Lexmark X500n, X502n Service Manual

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• Safety and notices

Lexmark X500n-X502n MFP

7100-XXX

• Trademarks

•Index

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

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dition: April 18, 2007 he following paragraph does not apply to any country where such provisions are inconsistent with local law:

EXMARK INTERNATIONAL, inC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,

ITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF

ERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or

mplied warranties in certain transactions; therefore, this statement may not apply to you.

his publication could include technical inaccuracies or typographical errors. Changes are periodically made to the

nformation herein; these changes will be incorporated in later editi ons. Improvements or changes in the products or the

rograms described may be made at any time.

omments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, exington, Kentucky 40550, U.S.A or e-mail at ServiceinfoAndTraining@Lexmark.com. Lexmark may use or distribute an f the information you supply in any way it believes appropriate without incurring any obligation to you.

eferences in this publication to products, programs, or services do not imply that the manufacturer intends to make thes vailable in all countries in which it operates. Any reference to a product, program, or service is not intended to state or

mply that only that product, program, or service may be used. Any functionally equivalent product, program, or service tha

oes not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in onjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the ser’s responsibility.

exmark, Lexmark with diamond design is a trademark of Lexmark international, inc., registered in the United States and r other countries.

ll other trademarks are the property of their respective owners.

2007 Lexmark International, Inc.

NITED STATES GOVERNMENT RIGHTS

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

P/N

12G9738

7100-XXX

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix

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

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

MFP Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

General device technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Print engine specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Scan specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Copy specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

Fax specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Standard inspection and cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

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

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

Understanding the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

User status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

MFP symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Printer service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

CPU fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Developer drive assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Transfer belt unit service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Transfer roller clutch service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Transfer belt cleaning roller clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Paper feed clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Registration clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

OPC belt marker sensor service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Erase lamp service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Power supply fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Fuser fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

High voltage power supply (HVPS) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Low voltage power supply (LVPS) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Fuser thermistor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Fuser assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Laser unit assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

HVPS connection service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Toner empty sensor (sender-TPD) service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

Toner empty sensor (receiver-TTR ) se rvic e ch eck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Lower feed unit (secondary paper assembly) service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Tray empty service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Paper tray missing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Toner low/empty service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Table of contents iii

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Waste toner bottle service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Missing toner cartridge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Missing photodeveloper cartridge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Transfer roller missing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

Cover open service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

OPC belt (photodeveloper) cartridge drive service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Missing fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Paper size sensing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

Printer no power service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

Toner feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

Waste toner feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

USB service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

Network service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

Black page copy service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

Flatbed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

ADF streak service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

ADF paper feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

Modem / fax card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43

Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

Printer paper feed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44

Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Background service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Back stain service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

Banding service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Black line service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

Color misregistration service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

insufficient fusing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50

insufficient gloss service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

Jitter service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Missing image at edge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

Mixed color image service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Mottle service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Residual image service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

Ribbing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

Smear service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

Toner drop service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59

Vertical line service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

Vertical staggering image service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

Vertical white band service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

White band service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

White line I service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

White line II service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

White spot / black spot service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

White print service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

Wrinkle / image migration service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67

Uneven density (right and left). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

Spacing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69

Roller specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

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

Understanding the MFP operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Retrieving, printing and restoring the MFP settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Printing the maintenance and configuration pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Setting the country code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

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Scanner calibration and registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Maintenance mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Display info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Print Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Scan Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Fax Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Density Tune Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Printer theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Electrophotographic Process (EP process). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

EP Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Summary of the EP process on the X500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

X500 EP steps in detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Paper path components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

X500n specific information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Paper jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Accessing jam areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Paper Jam A1, rear (tray 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Paper Jam A2, rear (tray 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Paper Jam B rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

Paper Jam C rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

ADF paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

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

Removal and cleaning precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Photodeveloper cartridge 4-3

During transportation/storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

MFP removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Cleaning roller cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Transfer belt cleaning roller removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Transfer belt unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Transfer roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Fuser assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Waste toner bottle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Photodeveloper cartridge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Secondary paper feed assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Front cover assembly remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Rear cover assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Left front cover removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Left rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Upper right rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Upper left rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Laser unit assembly (printhead) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Erase lamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Right side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Front door interlock switch with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Waste toner bottle holder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22

Developer drive assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Toner sensor (sender) removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

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Cleaning roller clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25

Main motor assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Clutch removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Main drive gear assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Waste toner feeder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Rear removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Bracket assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Paper guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Paper guide C assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Paper feed roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

Paper exit assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

Registration assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33

Left side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Engine controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

System board removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36

System board cage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38

High voltage power supply (HVPS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

Low voltage power supply (LVPS) with cage removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

HVPS cage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

Toner present sensor remov al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41

Toner sensor (receiver) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42

Left tray guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42

Modem speaker removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Fuser fan assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Modem card removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Top removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

Marker sensor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

Waste toner auger removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

Waste toner agitator removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47

Power supply fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48

Scanner assembly removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49

Flatbed assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49

Scanner arm removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52

ADF unit removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 53

ADF mechanism cover removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55

Operator panel removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57

Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Printer front and rear views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Scanner locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Printer engine sensor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

MFP circuit board locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Fan/motor and interlock switch locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

Clutch locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Symbol and part name table

Engine controller board wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

RIP board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

RIP card voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

Engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Low voltage power supply (LVPS) board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

High voltage power supply (HVPS) board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

Modem Card voltages and signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

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

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

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

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5

Table of contents vii

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viii Service Manual

Notices and safety information

The following laser notice labels may be affixed to this printer.

Laser notice

The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.

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

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). in anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (international Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.

7100-XXX

Laserprodukte der Klasse I gelten als unschädlich. Im inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.

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

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1.

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

Notices and safety information ix

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Avisos sobre el láser

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

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

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos laser da Classe I não são considerados perigosos. internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

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

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1 . Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der

nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

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Laserilmoitus

Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.

Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser , joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai huollon aikana.

Huomautus laserlaitteesta

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

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

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

7100-XXX

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

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon perso n utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.

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

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Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.

Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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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 composan ts 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 parti e 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.

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 tension e 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

7100-XXX

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 Segur i dad

• 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 este u

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

Safety information -xvii

7100-XXX

Lithium information

CAUTION: There is a lithium battery on your system board. RISK OF EXPLOSION IF REPLACED BY INCORRECT TYPE. The battery is non-replaceable. Do not replace,

recharge, disassemble, or incinerate a lithium battery. Discard used batteries according to the manufacturer’s instructions and local regulations.

Lithium-Information

ACHTUNG: Auf Ihrer Systemplatine befinde t sich ei ne Lithi umbatterie . Beim Einsetz en ei nes

nicht passenden Batterietyps besteht ein Explosionsrisiko. Die Batterie darf nicht ausgetauscht werden. Lithiumbatterien dürfen auf keinen Fall ausgetauscht, wieder aufgeladen, auseinander genommen oder verbrannt werden. Befolgen Sie zum Entsorgen verbrauchter Batterien die Anweisungen des Herstellers und die örtlichen Bestimmungen.

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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.

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:

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.

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1. General information

The Lexmark™ X500n and X502n are color laser MFPs that combine print, scan, copy, and fax functions. The X500n and X502n are the ideal MFPs f o r prese ntation s , b u siness g ra phics , line art, and text. The y use laser diode electrophotographic t echnology to deliver remarkable quality print images and text. The scan and copy functions work with A4 , letter, and legal (ADF only) size paper. Photographic quality images are possible with scan function. The FAX function delivers a wide range of functionality to the office user. The MFPs can be used as shared network or desktop devices.

Models

The Lexmark X5xx MFPs are available in the following models:

Model Configuration Machine type

X500n Print, copy, scan, networ k 7100-010 X502n Print, copy, scan, fax, network 7100-110

General information 1-1

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MFP Specifications

General device technical specifications

Interfaces

X500n X502n USB 2.0 X X Ethernet 10/100 Base T X X

Note: The USB 2.0 and network interfaces can be used simultaneously. The USB interface supports:

• Windows 98 SE

• Windows Me

• Windows NT

• Windows 2000 Professional

• Windows XP Operating Systems

• Windows Server 2003 Operating Systems

• Windows Vista 32/64 bit

• Macintosh OS X version10.1–10.4 (Power PC and Intel)

Note: For USB attachmen t, a USB ca ble (P/N 12A2405) is recommen de d a nd m u st b e o rde red sep arately.

The standard Ethernet connection and optional N2100 Series print servers support the following protocols:

• TCP/IP—The TCP/IP standard set of application services are supported including DHCP, BOOTP,

WINS, SNMP (MIB-2, host resources MI B , printer MIB , enterprise MIB, SNMP t ra ps), HTTP, LPR/LPD, FTP, IPP1,SLP, DDNS

• AppleTalk

This MFP with standard Ethernet supports an Embedded Web Server. The current status of the operator panel is viewable using the resident Web pages.

Processor

ARM-11core running at 366mhz.

Supported operating systems

This MFP is compatible with applications running under the following operating systems for either local or network connections:

Macintosh

• Macintosh OS X version 10.2–10.4 and above. (Power PC and Intel)

The software applications that operate with most Apple LaserWriter printers will generally operate with this printer.

Download the latest Lexmark printer PPD files or printer drivers from www.lexmark.com.

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Microsoft Windows

• Microsoft Windows Me

• Microsoft Windows 2000 Professional

• Microsoft Windows 2000 Server

• Microsoft Windows 2000 Advanced Server

• Microsoft Windows XP Home

• Microsoft Windows XP Professional

• Microsoft Windows Server 2003

• Microsoft Windows Vista 32/64 bit

Download the latest printer drivers from http://www.lexmark.com. The Windows software applications , which oper ate in the oper atin g systems liste d abo v e , ar e best suited to

run with the drivers supplied with this MFP. The drivers for Windows take advantage of the MFP’s functions and increase the MFP’s performance wherever possible.

Memory configuration

Standard DRAM 128MB Optional SDRAM N/A Max DRAM 128MB

Physical specifications and weight (WIP)

The following table contains the dimensions and weights for each MFP model and option. This does not include packaging but does include the print cartridge that ships with the MFP.

Width Depth Height Weight inch inch inch lb mm mm mm kg

MFP

Lexmark X500n/

X502n

Paper options

530-Sheet drawer 18.1 18.5 7.3 13.3

530-Sheet tray 11.2 14.4 4.5 4.2

Standard tray 10.8 13.0 2.2 2.2

Tray set to legal 10.8 15.9 2.2 2.4

Comes with standard input tray and starter cartridges.

Weight does not include packaging or pubs.

18.9 17.2 21 77.0 480 437 531 35.0

460 470 185 6.0

285 365 115 1.9

275 330 55 1.0

275 405 55 1.1

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Operating clearances

MFP sides X5xxn X5xxn with 530-sheet tray

Left side 8 in (203 mm) 8 in (203 mm) Right side 20 in (508 mm) 20 in (508 mm) Front 28 in (711 mm) 28 in (700 mm) Rear 10 in (254 mm) 10 in (254 mm) Top 16 in (400 mm) 16 in (400 mm)

Packaging and shipping dimensions

Width Depth Height Weight

MFP* in in in lb

mm mm mm kg

X500n / X502n 23.4 22.6 29.9 77

595 575 760 42.0 Options 530-Sheet drawer 21.9 22.4 10.9 18.7

556 570 277 8.5 * Includes start-up kit (supplies)

Power a nd electrical specifications

Printing states X5xxn

Off 0 W

Average power while operating

Continuous printing 670 W

Power consumption, standby

Power saver on 35 W Power saver off 200 W

Maximum current while operating

115 Volts 11 A 230 Volts 6 A

Average current while operating

115 Volts 6.0 A 230 Volts 3.0 A

1-4 Service Manual

Environment

Environment Specifications

Operating Air temperature–product operating 10 to 32.5°C (50 to 90.5°F) Air temperature–product power off 5 to 35°C (41 to 95°F) Air relative humidity 15 to 80% Altitude 0–2,500 m (0–8,200 ft.)

Ship / Storage Temperature-printer and supplies 0 to 35°C (32 to 95°F) Relative humidity 10 to 90% RH Atmospheric pressure 613 to 1607 hPa (460 to 800 mm Hg)

Severe High 35 to 40°C (95 to 104°F), Severe Low -10 to 0°C (14 to 32°F). The period under severe shall not be deemed to be

continuous, but rather a total of such intermittent periods (48 hours at most for any one period).

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General information 1-5

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Print engine specifications

Print engine resolution

600 x 600 dpi, 1200 x 600 dpi

Color balance settings

This MFP offers color balance control. It is a color correction option that allo ws you to increase or decrease the amount of toner going to the page for all four color planes. The scale ranges from -10 to +10.

Emulations

Raster Graphics (CMYK bi-tone JBIG Compressed)

Print engine speed and performance

Pages/minute)

Media size Standard tray

Mono Color Letter Up to 31 Up to 8 A4 Up to 31 Up to 8 Legal Up to 16 Up to 8 Transparencies Up to 3 Up to 2 Thick card stock Up to 3 Up to 2 Labels (letter &

A4) Medium thick card

stock (letter & A4) Envelopes Up to 5 Up to 3

Up to 5 Up to 3

Up to 4 Up to 3

Print engine time to first print

Media type/Media size First print time

Mono Color

Plain paper mode / A4, letter 13 seconds 19 seconds Transparency mode / A4, letter 23 seconds 29 seconds Label–middle thickness stock / A4, letter 17 seconds 23 seconds Middle thick stock–glossy / A4, letter 16 seconds 22 seconds Thick stock / A4, letter 23 seconds 29 seconds Envelope (1) mode / Commercial #10, International DL 18 seconds 24 seconds Envelope (2) mode / Commercial #10, International DL 23 seconds 29 seconds

Note: Note: Time to first page (TTFP) is the time from the moment when the host sends the print signal until the moment the trailing edge of the first page leaves the exit feed rollers. TTFP is measured using a simple text (single character) page.

Note: Note: Warm up time, 60 seconds maximum, is the time elapsed from when the power is turned on to when the Ready status is reached.

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Print engine paper and media specifications Print area

The printable area is up to 4.0 mm (0.158 in) from the top and bottom of the media, and up to 3.0 mm (0.118 in) from the left and right edges. Any information placed outside this specified printable area will not print. For envelopes, the printable area is up to 4.0 mm (0.158 in) of the left and right edges, and 3.0 mm (0.118 in) of the top and bottom edges.

Print engine input and output configurations

The following table shows the standard number of input sources and output destinations, as well as the estimated capacity of each. Capacity may vary and is subject to media specifications and MFP operating environment. The capacities listed are based on plain paper at 75 g/m

Sources and capacities X500n / X502n

Input sources Number of standard sources 1 Number of optional input drawers 1 Maximum number of input sources Maximum input capacity 780

Standard input

Primary tray capacity 250 Total standard capacity 250

Optional input

Optional tray 1 capacity 250 Optional tray 2 capacity 530

Number of standard destinations 1

Output capacities

Standard output bin capacity (top) Media up to 20 lb paper 250

Optional input drawer is a 530-sheet capacity drawer. Only one optional drawer may be installed at any time.

The MFP supports top output (facedown) as standard. No additional output options are available.

Note: All capacities are based on use of 20 lb paper.

Input capacities

Output destinations

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Media input types and weights

Source Type Standard tray

530–Sheet tray MFP menu Item

Legal tray

Paper

type

1,2

Paper (grain long)

Card stock Index 163 g/m

Index 164–210 g/m

Transparency

Labels

Envelopes 75–90

Punched, embossed, water-marked, perforated, punched, inkjet paper or plastic-coated media should not be used.

Only occasional use of paper labels in an office environment is supported.

Only PN 12A5940 and 12A5941 should be used.

Xerographic or bond paper

100% Cotton 75–120

60–74

g/m (16-19 lb)

75–120

(20-32 lb)

g/m

g/m (24-32 lb)

(90 lb)

(91-110 lb) PN 12A5940

PN 12A5941

g/m (20–24lb)

60–74

g/m (16-19 lb)

75–120 g/m2 (20-32 lb)

75–120

g/m (24-32 lb)

Plain paper Light

Plain paper Normal

Plain paper Heavy

N/A Card stock Normal

N/A Card stock Heavy

N/A Transparency

N/A Label N/A Envelope Normal

There is no automatic paper type sensing. These settings should be manually set in the operator panel.

Paper

weight

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Media sizes

Media sizes Dimensions Input Output

Universal 250-sheet tray 1Standard setting

Universal 250 sheet tray

Set to legal

Optional 530-sheet tray

Standard 250-sheet bin

mm in

A4 210 x 297 8.27 x 11.7 X X X X A5 148 x 210 5.83 x 8.2 7 X X

JIS B5 Letter 216 x 279.4 8.5 x 11 X X X X Legal 216 x 356 8.5 x 14 X X Executive 184.2 x 266.7 7.25 x 10.5 X X X X Folio 216 x 330 8.5 x 13 X X Statement 139.7 x 215.9 5.5 x 8.5 X X Universal

Standard 250–sheet letter tray 104.8 x 210 to 215.9 x

Optional 250–sheet legal tray 104.8 x 210 to 215.9 x

Envelope sizes Dimensions Dimensions 9 Envelope

COM 10 Envelope 104.8 x 241.3 4.12 x 9.5 X X X DL Envelope 110 x 220 4.33 x 8.66 X X X C5 Envelope B5 Envelope

Select Universal when using a non-standard size sheet of print material. The MFP formats the page for the maximum size 8.5 X 14

in(215.9 X 355.6 mm). Set the actual size from your software application.

Supported through the driver.

B5 may be supported in optional tray 1, but size sensing must be turned off.

2 2

182 x 257 7.17 x 10.1 X X X

XX X

4.125 x 8.27 to 8.5 x

297

11.7

4.125 x 8.27 to 8.5 x 14

355.6

98.4 x 225.4 3.875 x 8.9 X X X

162 x 229 6.38 x 9.01 X X X 176 x 250 6.93 x 9.84 X X X

Output capacity by media and source

Source Media Capacity Orientation

Standard output bin (top)¹ Supports all sizes listed in the “Media

sizes” table

250 sheets (20 lb paper) 50 Transparencies

Collated Facedown

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7100-XXX

Scan specifications

Resolution 1200 X 2400 dpi Scan size 216mm X 297 mm (flatbed), Window size 220mm X 300mm Scan depth 48 bits Lamp warm up time Less than 3 seconds MTF More than 30% Depth of focus -2 mm to +2 mm Magnification Less than 0.5% Scanning TWAIN Connectivity USB 2.0, and Ethernet (10/100 Base TX-TCP/IP only) Push scan Scan to E-mail, scan to FTP, scan to host PC Web status monitor Yes

Scanner driver (TWAIN) features

Scan mode True color, grayscale, black & white Contrast adjustment Yes Brightness adjustment Yes Color / Mono switch Yes

Scan to E-mail feature

Network requirements TCP/IP and an SMTP gateway Authorization function SMTP authentication, POP3 before SMTP Register E-mail address By Web page Scan destination Set up in scan profile E-mail address maintenance By Web page Job Search By profile name Subject input 20 characters maximum. Entered by the Web page interface Maximum E-mail data size Supported file formats TIFF, JPEG, PDF

1-10 Service Manual

Copy specifications

7100-XXX

Resolution 600 dpi X 600 dpi (flatbed), 600 X 300 dpi(ADF), Print from copy – 600 X 600 dpi

Original paper sizes A4, Letter, Legal (ADF only), B5 (JIS), Executive Copies per minute Mono: up to 21, Color: up to 7 Time to first copy Less than 30 seconds Multiple copies 99 copies maximum Output paper sizes A4, Letter, Legal (optional cassette only) Image density adjustment 5 levels, manual only Image quality modes Text, Photo, and Mixed Zoom 25% to 400% in increments of 1% Present reduction ratio US: 25%, 65%, 78%, 93%

Present enlargement ratio US: 129%, 155%, 200%, 400%

Advanced copier features

Combine multiple copies into one copy. 2 into 1, 4 into 1. Can be toggled between landscape and portrait. Electronic sort Yes Scan once print many Yes Limitless paper feed Yes Memory copy Standard Copy counter indicator Standard Jam recover auto restart For print jams only. Buzzer to finish job Yes

ADF

ADF width 5.5 to 8.5 inches (139.7 to 215.9 mm) ADF length 5.5 to 14 inches (139.7 to 355.6 mm) ADF capacity 35 sheets

- assumes 50% coverage

1 2 - Does not include scanner and printer warm-up time.

9600 dpi X 9600dpi w/ software interpolation

EU: 25%, 71%, 86%, 93%

EU: 122%, 141%, 200%, 400%

Fax specifications

Phone network connectivity

Phone networks types supported Both PSTN and PABX are supported. Compatibility T30(ITU-T Super G3) is supported.

Modem speed Automatic fallback: 33600 bps

Compression MH, MR, MMR, and JBIG

Color fax is not supported.

V34, V17, V29, and V27ter are supported for image transmission. V8, and V21 are supported for control channels.

General information 1-11

7100-XXX

Document Sizes supported

ADF width 5.5 to 8.5 inches (139.7 to 215.9 mm) ADF length 5.5 to 14 inches (139.7 to 355.6 mm) ADF capacity 35 sheets Flatbed width 8.5 inches (216 mm) Flatbed length 11.7 inches (297 mm) Scanning width 215.9 mm maximum Printing width Legal — 215.9 mm X 355.6 mm

Letter — 215.9 mm X 279.4 mm A4 - 210.0 X 297.0 mm

Fax scan resolutions

Horizontal

Fixation 200 dpi 8 dot/mm

Vertical

Standard 100 dpi 3.85 dot/mm Fine 200 dpi 7.7 dot/mm Photo 200 dpi 7.7 dot/mm

Miscellaneous FAX specifications

Halftone/error diffusion Error diffusion Speed dial 50 entries (name 20 characters, number 40 digits) Quick dial 20 entries (name 20 characters, number 40 digits) On hook dial Yes Direct Fax number entry Yes Re dial Yes

Transmission

Immediate transmission Yes Memory transmission Yes Page retransmission Yes Error correction mode Yes Broadcasting Yes (100 entries)

Reception

FAX only mode Yes Manual mode Yes Auto reduction Yes (Threshold 74%) Error correction mode Yes

Reports

Activity report Yes Transmission verification report Yes Power failure report Yes Phone book list Yes Quick dial list Yes Speed dial list Yes Memory manage list Yes User parameter list Yes

Clear memory transmission file

Memory job clear Standard All clear Standard

1-12 Service Manual

7100-XXX

Media guidelines

Paper designed f or use with x erog raphic copiers should provide satisf actory print quality and feed reliability. Other media types may be suitable. We recommend that users test any particular brand for suitability to their applications. Refer to the MFP User's Guide for additional med ia specifications.

Paper

• Rough, highly textured, limp, or pre-curled papers will result in lower print quality and more frequent

paper feed failures.

• Colored papers must be able to withstand 338°F (170°C) fusing temperature.

• Preprinted forms and letterheads should be selected using guidelines in the MFP User's Reference.

The chemical process used in preprinting may render some papers unsuitable for use with the MFP.

• Unsuitable papers include punched, embossed, water-marked, perforated media, any kind of inkjet

paper or plastic-coated paper.

• Recycled paper less than 75 g/m

The laser printing process heats paper to high temperatures of 170°C (338°F). 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 you have chosen is acceptable for laser printers.

(20 lb) may cause unacceptable results.

Envelopes

Should be fed with short edge first, flap down and to the right.

• If envelope wrinkling occurs, refer to the User's Reference for correct loading and stacking of

envelopes.

• All envelopes should be new, unused, and without damage.

• Envelopes with e xcessiv e curl or twist e xceeding 6.0 mm, those stuc k together, those with bent corners

or nicked edges, or those that interlock should not be used.

• Minimum weight: 90 g/m

(24 lb).

• The following envelopes should not be used:

– Envelopes with windows, holes, perforations, cutouts, or deep embossing – Envelopes with metal clasps, string ties, or metal folding bars – Envelopes with exposed flap adhesive when the flap is in the closed position – Self-seal envelopes

• Under high-humidity conditions (over 60%), the envelopes may seal during printing.

• For best results, print on new 90 g/m

Transparencies

(24 lb) sulfite or 25% cotton-bond envelope.

• Use letter (12A5940) or A4-size (12A5941) sheets only.

• Transparencies are only supported in tray 1 (standard or legal trays).

General information 1-13

7100-XXX

Labels

• Labels should be selected using guidelines found in the User's Guide, Complete Printer Guide, or the

Card stock & Label Guide (located at www.lexmark.com), and tested for acceptability.

• Vinyl labels are not supported.

• Labels are only supported in tray 1 (standard or legal trays).

Glossy Paper

• Use letter (12A5950) or A4-size (12A5951) sheets only.

• Glossy paper is only supported from tray 1 (standard or legal trays).

Sensing by source

Input Paper size Paper out Tray present

Integrated 250-sheet Optional 530-sheet

XXX XXX

1-14 Service Manual

Maintenance approach

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

• Printer messages

• Symptom tables

• Service checks

• Repair information

After you complete the repair, perform tests as needed to verify the repair. See “Diagnostic aids” on page 3-1.

Standard inspection and cleaning procedure

• Switch off printer power, and disconnect the AC power cord from the electrical outlet.

• Remove and inspect the photodevelopers and toner cartridges, shielding them from strong light.

• Inspect the interior of the printer , removing foreign matter such as pa per clips, staples, pieces of paper

or transparencies, paper dust, hair, oil, grease, or toner.

• Clean the printer interior using a lint-free cloth. Do not use solvents or chemical cleaners to clean the

printer interior.

• Use only the specified oil or lubricant on printer parts (some service parts are lubricated at the factory).

• Inspect and, if necessary, clean all rubber/plastic rolls with a lint-free cloth. Dry the rolls with a lint-free

cloth.

• While cleaning, inspect the interior of the printer for damaged wires, loose connections, toner leakage,

loose springs, and damaged or worn parts.

• Be sure the printer is on a single, flat, strong table or desk top.

• Inspect all supplies (OCR, cartridges, photodev elopers/toner cartridges, belts, fuser maintenance kits

and paper sources (cassettes, trays, feeders, duplex drawers, finisher, mailbox trays) for obvious damage and proper installation (paper guides not too tight). Inspect for correct media usage (paper, transparencies, labels).

• Print demo page.

• If additional paper sources are installed, print a demo page from each of these (if possible).

• Failure to print from an a dditional tray or feeder may imply one or more pi ns are bent in the mating

connector.

7100-XXX

General information 1-15

7100-XXX

Serial number

Look for serial number information on the right cover and the inside of the front cover of your MFP.

Tools required for service

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

• Analog volt ohmmeter (A digital volt ohmmeter may also be used.)

• Flat-blade screwdrivers

• Needle-nose pliers

• #1 Phillips screwdriver

• #2 Phillips screwdriver

• Slotted screwdriver #1

• Slotted clock screwdriver #1

• Tweezers, C-ring pliers

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

1-16 Service Manual

Acronyms

ADF Automatic document feeder ASIC Application specific integrated circuit BOOTP Boot protocol CCD Charge coupled device DDNS Dynamic domain name service DHCP Dynamic host configuration protocol DPI Dots per inch DRAM Dynamic random access memory EP Electrophotographic process ESD Electrostatic discharge FRU Field replaceable unit HTTP Hypertext transport protocol HV High voltage HVPS High voltage power supply JBIG Joint Bi-Level Image Experts Group LAN Local area network LASER Light amplification by simulated emission of

radiation LCD Liquid crystal display LED Light emitting diode LV Low voltage LVPS Low voltage power supply MFP Multiple function printer NVRAM Nonvolatile random access memory MH Message handling MMR Modified modified read MR Modem ready OEM Original equipment manufacturer PABX Private automatic branch exchange POR Power-on reset POST Power-on self test PQET Print quality enhancement technology PSTN Public switched telephone network RIP Raster image processor SMTP Simple mail transport protocol SDRAM Synchronous dynamic random access memory SNMP Simple network management protocol TAD Telephone answering device TCP/IP Transmission control protocol Internet protocol VAC Volts alternating current VDC Volts direct current WINS Windows internet name service

7100-XXX

General information 1-17

7100-XXX

1-18 Service Manual

7100-XXX

2. Diagnostic information

Start

CAUTION: Remov e po wer from th e printer bef ore y ou connect or disconne ct any cab le , electronic board or

assembly, for personal safety and to prevent damage t o the printer. Always use the hand grips on the side of the printer and be sure your fingers are not under the printer when you set the printer down.

Use the service error codes, user status messages, user error messages, symptom tables, service checks, and diagnostic aids, to determine the corrective action necessary to repair a malfunctioning printer.

Service error codes are indicated by a two-character alphanumeric error code. If a service error code displays, go to the “Service error codes” on page 2-3.

User status messages provide the user with information on the current status of the printer. “Ready” displays on the first line of the display unless Power Saver is invoked, then Power Saver is displayed. If a user status message displays, go to the “User attendance messages” on page 2-8.

User error messages are indicated by a two- or three-digit error code which provides the user with information explaining a problem with a print cartridge, paper jam, option, port, and so on. If a user error message displays, go to the“User attendance messages” on page 2-8.

The User Messages section sometimes allows a servicer to isolate printer problems. This section also giv es actions to be taken when they do not set or clear.

If you hav e a failing symptom, go to the “Symptom tables” on pa ge 2-11. Locate your symptom, and take the appropriate action.

If a service error code appears while you are working on the printer, go to the “Service error codes” on

page 2-3 and take the appropriate action.

Diagnostic information 2-1

7100-XXX

Understanding the operator panel

Using the MFP menus

Copy Settings

Paper Select Sort Density Quality Reduce/Enlarge

Scan Settings

Document Size Multi Page in A Document Limitless Scan Color Compress Ratio Resolution Density Limitation of size of mail

Machine Settings

Speaker Volume Paper Settings Job Timeout Auto Continue Toner Saver Mode Supplies info Scanner Carriage

Fax Settings

TX Settings RX Settings Tray Settings Delete Document Comm Settings Report Settings

Network Settings

Ethernet IP Configuration

Fax Directory

Quick Dial Entry Speed Dial Entry

Reports Print

Configuration Page Activity Report Memory List Quick Dial List Speed Dial List Scan Directory Scan Transmission Log Demo Page Maintenance Page

Admin Settings

Date /Time Setup User Settings TEL Line Type PBX Selection PBX Access Digit Default Mode Auto Clear Power Saver Display Language Country Code Setting Default Admin Menu Lock

2-2 Service Manual

Service error codes

Error code Action

7100-XXX

001 Service Call System Board - CPU

002 Service Call System Board - Flash

003 Service Call System Board - DRAM

004 Service Call System Board - RTC

009 Service Call System Board

005 Service Call Op Panel

006 Service Call Scanner Unit

007 Service Call Printer Communication Error

008 Service Call Fax Card

Replace the RIP board. See “System board removal” on page 4-36. Or replace the engine controller board. See“Engine controller board removal” on

page 4-34.

See “Operator panel service check” on page 2-40.

Scanner unit initialization failed. Home position not found. Possible scanner calibration failure. See “Flatbed service check” on page 2-41.

Print engine fails to initialize. See “Engine controller board removal” on

page 4-34.

Fax board f ails to initialize or f ails to respond when a fax is sent. See “Modem / fax

card service check” on page 2-43.

C3 Service Call Engine CTL Board

C4 Service Call Engine CTL Board

C7 Service Call Main Motor

D4 Service Call LV Power Supply

E0 Service Call Developer Motor 1 - MK

E1 Service Call Developer Motor 2 - CY

incorrect data is detected in the NVRAM during data confirmation process at power-on.

1. POR the machine.

2. If problem persists, replace the controller board. Defective engine controller board is causing faulty data transmission between ASIC

and CPU. POR the printer. If error still exists, replace the engine controller board. See

“Engine controller board removal” on page 4-34.

Synchronization signal from main motor is not detected. See “Main motor service check” on page 2-14.

See “Low voltage power supply (LVPS) service check” on page 2-23.

An over-current signal is detected due to an abnormal load on developer motor 1.

1. Replace black and magenta toner cartridge.

2. If error persists, see “Developer drive assembly service check” on

page 2-16.

An over-current signal is detected due to an abnormal load on developer motor 2.

1. Replace yellow and cyan toner cartridge.

2. If error persists, see “Developer drive assembly service check” on

page 2-16.

Diagnostic information 2-3

7100-XXX

Error code Action

E2 Service Call Main Motor

E3 Service Call Transfer Belt Sensor

E5 Service Call Transfer Roller Clutch

E6 Service Call Transfer Cleaner Solenoid

E7 Service Call P feed Clutch Tray 1

E8 Service Call Registration Clutch

E9 Service Call OPC Marker Sensor

EL Service Call Erase Lamp

A NOT READY signal (rotation error signal) is detected because of abnormal main motor rotation.

See “Main motor service check” on page 2-14. Unstable transfer belt rotation—color matching cannot be secured.

See “Transfer belt unit service check” on page 2-17. Improper transfer roller clutch cable connection or a shorted or cut cable.

See “T ransfer roller clutch service check” on page 2-18. Improper cleaning roller clutch cable connection or a shorted or cut cable.

See “Transfer belt cleaning roller clutch service check” on page 2-18. Improper paper-feed clutch cable connection or a shorted or cut cable.

See “Paper feed clutch service check” on page 2-19. Improper registration clutch cable connection or a shorted or cut cable.

See “Registration clutch service check” on page 2-19. Marker sensor is not properly detecting mark on OPC belt.

See “OPC belt marker sensor service check” on page 2-20. Improper erase lamp cable connection or a shorted or cut cable.

Erase lamp LED terminal may be cut. See “Erase lamp service check” on page 2-21.

F0 Service Call Power Supply Fan

F4 Service Call Fuser Fan

F5 Service Call HV Power Supply Unit

F6 Service Call LV Power Supply Unit

H0 Service Call Fuser Unit

H1 Service Call Fuser Unit

H2 Service Call Fuser Unit

H3 Service Call Fuser Unit

Improper fan motor rotation, improper fan motor cable connection or a shorted or cut cable.

See “Power supply fan service check” on page 2-22. Improper fan motor rotation, improper fan motor cable connection or a shorted or

cut cable. See “Fuser fan service check” on page 2-22.

Output (BRV) of HVPS is shorted, and or HVPS cable connector is improperly connected.

See “High voltage power supply (HVPS) service check” on page 2-23. Data communication error between LVPS and the engine controller board.

See “Low voltage power supply (LVPS) service check” on page 2-23. Temperature signal from thermistor is not detected.

See “Fuser thermistor service check” on page 2-24. Circuitry that controls the fuser temperature has failed.

See “Fuser assembly service check” on page 2-24. Fusing temperature is not reached within the warming-up time period.

See “Fuser assembly service check” on page 2-24 Fusing temperature drops below fusing threshold during the printing process and

does not reach fusing temperature again within alloted time . See “Fuser assembly service check” on page 2-24.

2-4 Service Manual

Error code Action

7100-XXX

H4 Service Call Fuser Unit

HA Service Call Fuser Unit

L1 Service Call Laser Unit Assembly

L2 Service Call Laser Unit Assembly

LL Service Call Laser Unit Assembly

N3 Service Call HVPS Connection

N4 Service Call Toner Empty Sensor

N5 Service Call Toner Empty Rcv

Fusing temperature rises above limit during printing process and does not return within the alloted time period.

See “Fuser assembly service check” on page 2-24. AC relay turned off due to an abnormal temperature.

See “Fuser assembly service check” on page 2-24. Laser scanning beam is not detected by beam sensor.

See “Laser unit assembly service check” on page 2-25. Scanner motor (SM) is rotating abnormally.

See “Laser unit assembly service check” on page 2-25. Laser power is lower than the output limit.

See “Laser unit assembly service check” on page 2-25. Improper connection between engine controller board and HVPS.

See “HVPS connection service check” on page 2-25. Improper connection between engine controller board and toner sensor sender

board. See “T oner empty sensor (sender-TPD) service chec k” on page 2-26.

Improper connection between engine controller board and toner sensor receiver board.

See “T oner empty sensor (receiver-TTR) service check” on page 2-27.

N6 Service Call LFU Connection

P6 Service Call Pfeed Clutch Tray 2

Improper connection between engine controller board and lower paper feed unit. See “Lower feed unit (secondary paper assembly) service check” on

page 2-28.

Data communication error between engine controller board and LFU paper-feed clutch.

See “Lower feed unit (secondary paper assembly) service check” on

page 2-28.

Diagnostic information 2-5

7100-XXX

User status messages

Message Description Action

Tray (1, 2) Missing The upper or lower tray is

missing.

Toner Low (C,M,Y,K) The toner is low in the

cartridge indicated. Sleep The MFP is idle. These are the normal operating modes. Please Wait The MFP is warming up. READY The MFP is ready to

perform a task. PC Printing The MFP is printing. Calibrating The MFP is calibrating. Connected to Server The MFP is connected to

a server for a push scan

job. Sending File... A scan job is being

transmitted. Send E-mail Notification An e-mail is being sent to

a user notifying them of a

push scan job being

completed.

install the upper or lower tray. If the problem persists, see “Paper tray missing service

check” on page 2-30.

See “Toner low/empty service check” on

page 2-31.

Connection Fail Unable to connect to the

No Response The device Busy The remote fax device is

Dial Failed The dial attempt to

Scanning Page The scanner is scanning

Job # Fax Job # is being

Dialing A fax number is being

Awaiting Re dial The fax is between dialing

Transmitting The fax is transmitting

Receiving The X502 is receiving fax

remote fax.

currently busy.

another device failed.

in the flatbed or ADF.

processed.

dialed.

attempts.

data to another fax device.

data from a remote fax

device.

2-6 Service Manual

Message Description Action

7100-XXX

TAD Answering A telephone call is being

received.

Answering The fax is answering an in

coming call.

incoming Call There is an incoming call

on the phone line

Warming Up The MFP is warming up.

These are the normal operating modes.

Diagnostic information 2-7

7100-XXX

User attendance messages

Message Description Action

Paper Empty (Load Tray - Paper Size, Load

Tray 1 Paper Size, Load Tray 2 Paper Size, Load Tray Paper)

Paper Change Load Paper <Type, Size>

Paper Error Load Tray 1 <Paper Type> Tray (1, 2) Missing The upper or lower tray is

Toner Low (C,M,Y,K) The toner is low in the

C/M/Y/K Toner Empty Replace Toner C/M/Y/K

Waste Pack Full The waste toner bottle is

The upper or lower paper

tray is empt y or the me dia

in the trays is inconsistent.

Media size and type

mismatch.

Media type mismatch. Load the paper tray with the correct media type.

missing.

cartridge indicated.

The specific toner

cartridge needs to be

replaced. in most cases,

only one of the letters

CYMK will appear.

full or not installed.

Fill up the paper tray(s) or replace the media with the correct type. If the problem persists, see

“Tray empty service check” on page 2-29.

• Check the media size.

• Check the media size setting in the cassette.

• Check to make sure the media setting on the printer and drive match the media in the cassette.

install the upper or lower tray. If the problem persists, see “Paper tray missing service

check” on page 2-30.

See “Toner low/empty service check” on

page 2-31.

install the appropriate toner cartridge. If prob l em persists, see “Toner low/empty service check”

on page 2-31.

install the waste toner bottle or re pl a c e the full waste toner bottle. If problem persists, see

“Waste toner bottle service check” on page 2-31.

OPC Exhausted Replace OPC Belt OPC Belt Life Replace OPC Belt Fuser Life Replace Fuser TR Belt Life Replace Transfer Belt Missing install Fuser Unit

2-8 Service Manual

Replace with a new OPC unit.

Replace with a new fuser unit.

Replace with a new transfer belt unit.

The fuser is not installed. If fuser is installed, remove it and reinstall. If

See “Photodeveloper cartridge removal” on

page 4-8.

See “Photodeveloper cartridge removal” on

page 4-8.

See “Fuser assembly removal” on page 4-6.

See “Transfer belt unit removal” on page 4-5.

problem persists, check the cable that connects engine controller board connector FUCN and fuser. If the cable is bad, replace the cable. Otherwise, replace the engine controller board. See “Engine controller board removal” on

page 4-34.

Message Description Action

7100-XXX

Toner Error install Supported Cartridge Missing install Toner (C,M,Y,K)

Missing install OPC Belt

Missing install Transfer Roller Paper Jam A 1-2 Paper is jamming at

Paper Jam B Paper is jamming inside

Paper Jam C Paper is jamming at paper

Cover Open Close (Front, Rear, OPC)

An invalid toner cartridge is installed.

A toner cartridge is not keyed properly.

The OPC belt cartridge is not installed.

The transfer rol ler is not installed.

feeding area.

the MFP.

exit area. The back, front, or OPC

cover is open.

install a supported cartridge. If the problem persists, see “Missing toner cartridge service

check” on page 2-32.

install proper brand of toner cartridge. If problem persists, see “Missing toner cartridge service

check” on page 2-32.

Correctly install the photodeveloper cartridge to clear message and continue printing. If error persists, see “Missing photodeveloper

cartridge service check” on page 2-33.

Ensure transfer roller is properly installed. If problem persists, see “Transfer roller missing

service check” on page 2-34.

See “P aper Jam A1, rear (tray 1)” on page 3-24 or “Paper Jam A2, rear (tray 2)” on page 3-26 for instructions to clear the jam.

See “Paper Jam B rear” on page 3-27 fo r instructions to clear the jam.

See “Paper Jam C rear” on page 3-29 fo r instructions to clear the jam.

Close specified cover if open. If not open, open the cover and close. If the problem persists, see

“Cover open service check” on page 2-35.

TR Belt Life Replace Transfer Belt TR Kit Life Replace PQ Kit

PF1 Kit Life Replace PF Kit 1

PF2 Kit Life Replace PF Kit 2

ADF Jam Open ADF cover and Clear Jam

ADF Cover Open Close ADF cover

Scan Calibration Error Scanner is out of

Scan Lock Error Unlock Scanner

The transfer belt is at its end of life.

The transfer roll and transfer belt cleaning roll have reached the end of life.

The paperfeed roll and separator pad in tray 1 are at the end of life.

The paperfeed roll and separator pad in tray 2 are at the end of life.

A sheet of paper is jammed in the ADF.

The ADF cover is open. Close the ADF cover. If the cover is already

calibration. The scanner lock is in the

locked position.

Replace the transfer belt. See “Transfer belt

unit removal” on page 4-5.

Replace the transfer roll. See “Transfer roller

removal” on pa ge 4-6. Also, replace the transfer

belt cleaning roller. See “Transfer belt cleaning

roller removal” on page 4-4.

Replace the paperfeed roll and the separator pad for the respective paper tray (1 or 2). See “Paper

feed roller removal” on page 4-32.

Clear the ADF jam. If the message persists, see

“ADF streak service check” on page 2-41.

closed, see “ADF streak service check” on

page 2-41.

Perf orm scanner calibration.

Unlock the scanner. If the scanner lock is in the unlocked position, see “Flatbed service check”

on page 2-41.

Diagnostic information 2-9

7100-XXX

Message Description Action

Scan USB Disconnect The USB connection is

disconnected.

Scan Network Disconnect The network connection is

disconnected.

Duplicate IP Address Found Another device using an

identical IP address has been detected on the

network. E-mail Size Limit Exceeded E-mail memory buffer full. Retry the job. Break it up if needed. Out of Memory Memory depleted. Retry the print job. Break it up if needed. Scan Memory Full Memory for the scan job is

full. Communication Error Communication with host

machine failed. Server Connection Failed Communications with the

server failed. (TX / RX) Comm Error There is a data

transmission or reception

error. CPU fan locked The CPU fan is no longer

running on the RIP card.

See “USB service check” on page 2-40.

See “Network service check” on page 2-40.

Contact the network administrator.

Break the scan job into smaller segments.

Retry the job. Check all connections with the host device.

Resend the fax.

See “CPU fan service check” on page 2-16.

Note: The expected yield of the separator pad and paperfeed roll are 120,000 pages.

2-10 Service Manual

Symptom tables

MFP symptom table

Symptom Action

Paper feed problems See “Paper feed service checks” on page 2-44. Close door displayed when all doors are closed. See “User attendance messages” on page 2-8, and

follow the action suggested.

7100-XXX

Paper jam messages do not reset after removing paper.

Toner cartridge does not turn or does not put toner on the photodeveloper cartridge.

Developer motor makes noise or continuously runs. See “Developer drive assembly service check” on

Main motor makes noise or continuously runs. See “Main motor service check” on page 2-14. T r ansfer belt unit makes noise when rotated or does not

rotate at all. The transfer roll is not transferring images or does not

turn. No power See “Printer no power service check” on page 2-38. Waste toner feed problems See “Waste toner feed service check” on page 2-39. Fans not working or making noise. See “Service error codes” on page 2-3. Find the failing

Print/image problems See “Print quality symptom table” on page 2-13. Photodeveloper cartridge does not rotate or makes

noise. Black copies from scanner. See “Black page copy service check” on page 2-41.

See “User attendance messages” on page 2-8, and follow the action suggested.

See “Toner feed service check” on page 2-39.

page 2-16.

See “Transfer belt unit service check” on page 2-17.

See “White band service check” on page 2-63.

fan, and follow the action suggested.

See “OPC belt (photodeveloper) cartridge drive service

check” on page 2-36.

Fail to scan from the flatbed. See “Flatbed service check” on page 2-41. Paper jams in the ADF. See “ADF paper feed service check” on page 2-42. Paper skews when fed into the AD F. See “ADF paper feed service check” on page 2-42. Paper fails to f eed into the ADF. See “ADF paper feed service check” on page 2-42. Op panel failure See “Operator panel service check” on page 2-40. Fax fails to transmit. See “Modem / fax card service check” on page 2-43. Fax appears stretched or compressed. Issue with sending fax machine. Streaks down the middle of a copy, fax or scan when

using the ADF Scanner locked Check the scanner lock switch. If it is unlocked see

Scanner fails to communicate with the host PC. If the MFP is USB-attached, see “USB service check” on

See “ADF streak service check” on page 2-41.

“Flatbed service check” on page 2-41.

page 2-40. If the MFP is network-attached, see “Network service check” on page 2-40.

Diagnostic information 2-11

7100-XXX

Symptom Action

No dial tone when sending a fax. See “Modem / fax card service check” on page 2-43. Lines on outbound fax documents Check the flatbed glass for scratches or marks. Words and images on inbound fax documents are

stretched out.

The sending machine had a temporary jam.

2-12 Service Manual

Print quality symptom table

Symptom Action

Background See “Background service check” on page 2-45. Missing image at edge See “Missing image at edge service check” on page 2-53. Jitter See “Jitter service check” on page 2-52. Ribbing See “Ribbing service check” on page 2-57. Wrinkle and image migration See “Wrinkle / image migration service check” on page 2-67. White line See “White line II service check” on page 2-64. White line See “White line II service check” on page 2-64. V e rtical white band See “Vertical white band service check” on page 2-62. Black line See “Black line service check” on page 2-48. V ertical line See “Vertical line service check” on page 2-60. V e rtical staggering image See “Vertical staggering image service check” on page 2-61.

7100-XXX

Banding See “Banding service check” on page 2-47. White band See “White band service check” on page 2-63. Toner drop See “Toner drop service check” on page 2-59. White spots and black spots See “White spot / black spot service check” on page 2-65. Mixed color image See “Mixed color image service check” on page 2-54. Color misregistration See “Color misregistration service check” on page 2-49. Mottle See “Mottle service check” on page 2-55. Residual image See “Residual image service check” on page 2-56. Insufficient gloss See “insufficient gloss service check” on page 2-51. Back stain See “Back stain service check” on page 2 -46 . White print See “White print service check” on page 2-66. Insufficient fusing See “insufficient fus ing se rvice check” on page 2-50.

Diagnostic information 2-13

7100-XXX

Printer service checks

Main motor service check

Step Questions / actions Yes No

1 Turn printer off and remove right cover. See

“Right cover removal” on page 4-13.

Open top cover and override top cover interlock switch. Restart printer, and observe main motor and photodeveloper cartridge OPC belt. Does main motor attempt to turn but OPC belt will not rotate?

2 Observe main motor and fuser . Does main

motor attempt to turn but fuser will not?

3 Are there any unusual noises around main

motor before error posts?

4 Does noise go away? Problem solved. Go to step 5. 5 Is cable properly connected to main motor? Go to step 6. Properly connect cable.

6 If waste toner bo ttle is removed, reinsert it.

Ensure rear cover assembly cover is shut. Override top and front cover interlock switches. For location, see “Fan/moto r and

interlock switch locations” on page 5-6.

Reconnect operator panel. Turn printer on. Allow printer to run until error posts. Disconnect connector from main motor, and check the following on disconnected cable connector:

Replace photodeveloper cartridge.

Note: photodeveloper cartridge is a customerordered supply.

Replace fuser assembly. See “Fuser assembly

removal” on page 4-6.

Note: Fuser is a customer-

ordered supply. Replace main motor. See

“Main motor assembly removal” on page 4-26.

Go to step 4.

Replace main motor. See

“Main motor assembly removal” on page 4-26.

Go to step 9.

Go to step 2.

Go to step 3.

Go to step 5.

Retest printer. If error clears, problem solved, otherwise go to step 6.

Go to step 7.

Pin 4 to pin 5—24VDC Pin 6 to pin 5—24VDC Pin 10 to pin 5—5VDC

Are voltages present?

7 Remove engine controller board shield. See

“Engine controller board removal” on page 4-34 for steps to remove engine

controller board shield. Disconnect MCN5 from engine controller board. Check for continuity and shorted pins on cable that connects MCN5 to main motor. Is cable okay?

2-14 Service Manual

Go to step 8. Replace cable. Retest

printer. If error clears, problem solved, otherwise go to step 8.

Step Questions / actions Yes No

7100-XXX

8 Disconnect cable from engine controller

board POCN. Check the following on disconnected cable connector:

Pin 21 to pin 22—24VDC Pin 13 to pin 14—5VDC

Are voltages present?

9 Reassemble and retest printer. Does error

clear?

Replace engine controller board. See “Engine

controller board removal” on page 4-34. Go step 9.

Problem solved. Contact next level of

Replace cable that connects ACN1 on LVPS to POCN on engine controller board. Remove RIP board cage to gain access to cable. See “System board

cage removal” on page 4-38. Go to step 9.

support.

Diagnostic information 2-15

7100-XXX

CPU fan service check

Step Questions / actions Yes N o

1 Open the RIP cage cover. Is the CPU fan

spinning?

2 Is the CPU fan cable properly connected to

J-Fan1 on the RIP board?

No issue to fix. Go to step 2.

Connect the cable to JFan1.

Replace the RIP board. See

“System board removal” on page 4-36.

Developer drive assembly service check

Step Questions / actions Yes No

1 Are there any unusual noises heard around

developer motor or developer drive assembly before error posts?

2 Does noise go away? Problem solved. Replace developer drive

3 Does noise go away? Problem solved. Go to step 4. 4 Turn printer off, and remove right cover . See

“Right cover removal” on page 4-14. Is

cable properly connected to developer drive assembly motor?

5 If waste toner bo ttle is removed, reinsert it.

Ensure rear cover assembly is shut. Override top and front cover interlock switches. For location, see “Interlock

switch locations” on page 5-6. Reconnect

operator panel. Turn printer on. Allow printer to run until error posts. Disconnect connector from each developer motor, and check for the following on each disconnected cable connector:

Replace toner cartr idge (customer-ordered supply). Go to step 2.

Go to step 5. Properly connect cable.

Replace developer drive assembly. See “Developer

drive assembly removal” on page 4-21. Go to step 8.

Go to step 4.

assembly. See “Developer

drive assembly removal” on page 4-22. Go to step 3.

Retest printer. If error clears, problem solved, otherwise go to step 5.

Go to step 6.

Pin 2 to ground—24VDC Pin 5 to ground—24VDC

Are voltages present?

6 Remove engine controller board shield. See

“Engine controller board removal” on page 4-34 for steps to remove engine

controller board shield. Disconnect MCN5 from engine controller board. Check for continuity and shorted pins on cable that connects MCN5 to developer motors. Is cable okay?

2-16 Service Manual

Go to step 7. Replace cable. Retest

printer. If error clears, problem solved, otherwise go to step 7.

Step Questions / actions Yes No

7100-XXX

7 Disconnect cable from engine controller

board POCN. Check the following on disconnected cable connector:

Pin 21 to pin 22—24VDC Pin 13 to pin 14—5VDC

Are voltages present?

8 Reassemble and retest printer. Does error

clear?

Replace engine controller board. See “Engine

controller board removal” on page 4-34. Go step 8.

Problem solved. Contact next level of

Replace cable that connects ACN1 on LVPS to POCN on engine controller board. Remove RIP board cage to gain access to cable. See “System board

cage removal” on page 4-38. Go to step 8.

support.

Transfer belt unit service check

Step Questions / actions Yes No

1 Open rear cover assembly, and check

transfer belt unit markers for stains. Are markers stained?

2 Remove transfer belt unit, and observe

markers on side. Are belt markers deformed or does transfer belt seem hard to rotate?

3 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Are cables properly connected to engine controller board connectors MCN9 and POCN?

Clean belt marker area wi th cotton cloth. If problem persists, go to step 2.

Replace transfer belt unit. See “Transfer belt unit

removal” on page 4-5.

Go to step 4. Properly connect cables. If

Go to step 2.

Reinstall transfer belt unit. Go to step 3.

problem persists, go to step

4 Ensure rear cover assembly and front cover

assembly are closed. Override top interlock switch, and turn printer on. Wait until printer displays error, and remove MCN9 from engine controller board. Check for 5 VDC between MCN9 pin 1 (on engine controller board) and ground (you can touch negative lead of voltmeter to metal frame to obtain ground.) Is voltage present and correct?

5 On engine controller board, reconnect

MCN9 and disconnect cable from POCN. On cable disconnected from POCN, check for 5 VDC from pin 13 to ground (you can touch negative lead of voltmeter to metal frame to obtain ground.) Is voltage present and correct?

Engine controller board is providing 5 VDC to marker sensor. Replace transfer belt marker sensor. Marker sensor is part of a bracket assembly. See “Bracket

assembly removal” on page 4-30. If problem

persists, replace engine controller board. See

“Engine controller board removal” on page 4-34.

LVPS is providing 5 VDC to engine controller board. Replace faulty engine controller board. See

“Engine controller board removal” on page 4-34.

Go to step 5.

Replace LVPS. See “Low

voltage power supply (LVPS) with cage removal” on page 4-40.

Diagnostic information 2-17

7100-XXX

Transfer roller clutch service check

Step Questions / actions Yes N o

1 Turn printer off and remove printer right

cover. See “Right cover remov a l” on

page 4-13. Is cable properly connected to

transfer roller clutch?

2 Disconnect transfer roller clutch from cable.

Measure resistance between two outer pins on transfer roller clutch. Does resistance measure between 119 and 145 ohms?

3 Remove engine controller board shield. See

“Engine controller board removal” on page 4-34 for steps to remove engine

controller board shield. Disconnect cable from MCN4 on engine controller board. Check cable continuity from MCN4 pins 5 and 6 (cable) to connector that attaches to transfer roller clutch. Ensure that pins are not shorted. Is cable okay?

Go to step 2. Properly connect cable. If

Go to step 3. Replace faulty transfer

Replace engine controller board. See “Engine

controller board removal” on page 4-34. If problem

persists, replace faulty transfer roller clutch. See

“Clutch removal” on page 4-27.

problem persists, go to step

roller clutch. See “Clutch

removal” on page 4-27.

Replace cable. If problem persists, replace faulty transfer roller clutch. See

“Clutch removal” on page 4-27.

Transfer belt cleaning roller clutch service check

Step Questions / actions Yes No

1 Turn printer off, and remove printer right

cover. See “Right cover removal” on

page 4-13. Is cable properly connected to

cleaning roller clutch?

Go to step 2. Properly connect cable. If

problem persists, go to step

2 Disconnect transfer belt cleaning roller

clutch from cable. Measure resistance between two outer pins on cleaning roller clutch. Does resistance measure between 198 and 242 ohms?

3 Remove engine controller board shield. See

“Engine controller board removal” on page 4-34 for steps to remove shield.

Disconnect cable from MCN4 on engine controller board. Check cable continuity from MCN4 pins 1 and 2 (cable) to connector that attaches to cleaning roller clutch. Ensure that pins are not shorted. Is cable oka y ?

Go to step 3. Replace faulty cleaning

roller clutch. See

“Cleaning roller clutch removal” on page 4-25.

Replace engine controller board. See “Engine

controller board remo val” on page 4-34. If problem

persists, replace faulty cleaning roller clutch. See

“Cleaning roller clutch removal” on page 4-25.

Replace cable. If problem persists, replace faulty cleaning roller clutch. See

“Cleaning roller clutch removal” on page 4-25.

2-18 Service Manual

Paper feed clutch service check

Step Questions / actions Yes No

7100-XXX

1 Turn printer off, and remove printer right

cover. See “Right cover removal” on

page 4-13. Is cable properly connected to

paper feed clutch?

2 Disconnect paper feed clutch from cable.

Measure resistance between two outer pins on paper feed clutch. Does resistance measure between 119 and 145 ohms?

3 Remove engine controller board shield. See

“Engine controller board removal” on page 4-34 for steps to remove engine

controller board shield. Disconnect cable from MCN4 on engine controller board. Check cable continuity from MCN4 pins 9 and 10 (cable) to outer pins on connector that attaches to paper feed clutch. Ensure that pins are not shorted. Is cable okay?

Go to step 2. Properly connect cable. If

Go to step 3. Replace faulty paper feed

Replace engine controller board. See “Engine

controller board remo val” on page 4-34. If problem

persists, replace faulty paper feed clutch. See

“Clutch removal” on page 4-27.

problem persists, go to step

clutch. See “Clutch

removal” on page 4-27.

Replace cable. If problem persists, replace faulty paper feed clutch. See

“Clutch removal” on page 4-27.

Registration clutch service check

Step Questions / actions Yes No

1 Turn printer off, and remove printer right

cover. See “Right cover removal” on

page 4-13. Is cable properly connected to

registration clutch?

Go to step 2. Properly connect cable. If

problem persists, go to step

2 Disconnect registration clutch from cable.

Measure resistance between two outer pins on paper feed clutch. Does resistance measure between (****check these values) 119 and 145 ohms?

3 Remove engine controller board shield. See

“Engine controller board removal” on page 4-34 for steps to remove engine

controller board shield. Disconnect cable from MCN4 on engine controller board. Check cable continuity from MCN4 pins 7 and 8 (cable) to outer pins on connector that attaches to registration clutch. Ensure that pins are not shorted. Is cable okay?

Go to step 3. Replace registration clutch.

See “Clutch removal” on

page 4-27.

Replace engine controller board. See “Engine

controller board remo val” on page 4-34. If problem

persists, replace faulty registration clutch. See

“Clutch removal” on page 4-27.

Replace cable. If problem persists, replace faulty registration clutch. See

“Clutch removal” on page 4-27.

Diagnostic information 2-19

7100-XXX

OPC belt marker sensor service check

Step Questions / actions Yes N o

1 Remove photodeveloper cartridge and

check for defects. Does photodeveloper appear okay?

2 Obse rve markers on side. Are belt markers

covered with foreign particles?

3 Reinstall photodeveloper cartridge. Turn

printer off, and remove engine controller board shield. See “Engine controller

board removal” on page 4-34 for steps to

remove engine controller board shield. Is cables MCN7 properly connected to engine controller board?

4 Ensure rear cover assembly and front cov e r

assembly are closed. Override top interlock switch, and turn printer on. Wait until printer displays error, and remove MCN7 from engine controller board. Check for 5 VDC between MCN7 pin 3 (on engine controller board) and ground (you can touch negative lead of voltmeter to meta l frame to obtain ground.) Is voltage present and correct?

5 Reconnect MCN7, and disconnect cable

from POCN. On disconnected cable, check for 5 VDC on cable pin corresponding to POCN pin 13. You can touch negative lead of voltmeter to metal frame to obtain ground. Is voltage present and correct?

Go to step 2. Replace photodeveloper

Clean marker area with cotton cloth. If problem persists, go to step 3.

Go to step 3. Properly connect cable. If

Engine controller board is providing 5 VDC to OPC sensor. Replace OPC marker sensor. See

“Marker sensor assembly removal” on page 4-46. If

problem persists, replace engine controller board. See “Engine controller

board removal” on page 4-34.

LVPS is providing 5 VDC to engine controller board. Replace engine controller board. See “Engine

controller board removal” on page 4-34.

cartridge.

Go to step 3.

problem persists, go to step

Go to step 5.

Go to step 6.

6 Turn printer off. Disconnect cable that

connects LVPS ACN1 to engine controller board POCN, and check for continuity, shorted pins, or any other cable damage. Is cable okay?

2-20 Service Manual

Replace LVPS. See “Low

voltage power suppl y (LVPS) with cage removal” on page 4-40.

Replace cable.

Erase lamp service check

Step Questions / actions Yes No

7100-XXX

1 Turn printer off, and remove toner cartridges

and photodeveloper cartridge. Check erase lamp cable for proper connection. Is erase lamp cable properly connected?

2 Check erase lamp for any visib le damage. Is

erase lamp damaged?

3 Set multimeter to check diodes. Looking at

erase lamp through front cover, touch meter positive lead to left LED connection and meter negative lead to right LED connection. LED should illuminate. Check all LEDs on erase lamp board. Do any LEDs fail to illuminate?

4 Remove engine controller board shield. See

“Engine controller board removal” on page 4-34 for steps to remove engine

controller board shield. Is cable properly connected to engine controller board connector MCN8?

Go to step 2. Properly connect erase

lamp. Retest printer. If error clears, problem solved, otherwise go to step 2.

Replace erase lamp. See

“Erase lamp removal” on page 4-20. Retest printer. If

error clears, problem solved, otherwise remove toner cartridges and photodeveloper cartridge and go to step 3.

Replace erase lamp. See

“Erase lamp removal” on page 4-20. Retest printer. If

error clears, problem solved, otherwise go to step

Go to step 5. Properly connect cable.

Go to step 3.

Go to step 4.

Retest printer. If error clears, problem solved, otherwise go to step 5.

5 Disconnect cable from erase lamp and

engine controller board MCN8. Check for continuity between cable pin that corresponds to MCN8 pin 11 and erase lamp cable connector pin 3. Also check for continuity between cable pin that corresponds to MCN8 pin 12 and erase lamp cable connector pin 1. Check for shorted pins on both sides of cable. Is cable okay?

6 Retest printer. Does error clear? Problem solved. Contact higher level

Replace engine controller board. See “Engine

controller board removal” on page 4-34. Go to step 6.

Replace cable. Retest printer. Go to step 6.

support.

Diagnostic information 2-21

7100-XXX

Power supply fan service check

Step Questions / actions Yes No

1 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Is cable properly connected to engine controller board connector MCN10?

2 Ensure rear cover assembly cover is shut.

Override top and front cover interlock switches. Fo r location, see “Fan/motor and

interlock switch locations” on page 5-6.

Turn printer on, and check for 24VDC between engine controller board MCN10 pin 1 and power ground (you can touch negative lead of voltmeter to metal frame to obtain ground.) Is voltage present and correct?

3 Turn printer off, and disconnect cable from

engine controller board MCN10 and power supply fan. Check cable for continuity and pin shorts. Is cable okay?

Go to step 2. Properly connect cable.

Replace power supply fan assembly. See “Power

supply fan removal” on page 4-48. Retest printer. If

error clears, problem solved, otherwise go to step

Replace engine controller board. See “Engine

controller board removal” on page 4-34.

Go to step 3.

Replace cable.

Fuser fan service check

Step Questions / actions Yes N o

1 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Is cable properly connected to engine controller board connector MCN1?

2 Ensure rear cover assembly cover is shut.

Override top and front cover interlock switches. F or location, see “F an/motor and

interlock switch locations” on page 5-6.

Reconnect operator panel. Turn printer on, and check for 24VDC between engine controller board MCN1 pin 4 and power ground (you can touch negative lead of voltmeter to metal frame to obtain ground.) Is voltage present and correct?

3 Turn printer off, and disconnect cable from

engine controller board MCN1 and power supply fan. Check cable for continuity and pin shorts. Is cable okay?

Go to step 2. Properly connect cable.

Potentially faulty fuser fan. Replace rear cover assembly. See “Rear

cover assembly removal” on page 4-14. Retest

printer. If error clears, problem solved, otherwise go to step 3.

Replace engine controller board. See “Engine

controller board removal” on page 4-34.

Go to step 3.

Replace cable.

2-22 Service Manual

High voltage power supply (HVPS) service check

Step Ques tions / actions Yes No

7100-XXX

1 Remove photodeveloper cartr idge,

and ensure charging unit on bottom of photodeveloper cartridge is not damaged. Is charging unit damaged?

2 Check charging unit high voltage

contacts in printer. Are they clean?

3 Replace photodeveloper cartridge.

See “Photodeveloper cartridge

removal” on page 4-8. Has error

cleared? Note: photodeveloper cartridge is a

customer-ordered part.

4 Check cable for continuity between

engine controller board connector HVCN and HVPS BCN1 connector and for shorted pins. Is cable okay?

5 Replace HVPS. See “High voltage

power supply (HVPS) removal” on page 4-39. Has error cleared?

6 Replace engine controller board.

See “Engine controller board

removal” on page 4-34. Has error

cleared?

Replace photodeveloper cartridge. See

“Photodeveloper cartridge removal” on page 4-8.

Note: photodeveloper

cartridge is a customerordered part.

Go to step 3. Clean contacts. If problem

Problem solved. Go to step 4.

Go to step 5. Replace cable.

Problem solved. Go to step 6.

Problem solved. Contact higher level support.

Go to step 2.

persists, go to step 3.

Low voltage power supply (LVPS) service check

Step Questions / actions Yes No

1 Check cable for continuity between engine

controller board connector LVCN and LVPS ACN4 connector. Also check for shorted pins. Is cable oka y ?

2 Replace LVPS. See “Low voltage power

supply (LVPS) with cage removal” on page 4-40. Does problem persist?

3 Replace engine controller board. See

“Engine controller board removal” on page 4-34. Does problem persist?

Go to step 2. Replace cable.

Go to step 3. Problem solved.

Contact higher level support.

Problem solved.

Diagnostic information 2-23

7100-XXX

Fuser thermistor service check

Step Questions / actions Yes No

1 Remove and reinstall fuser assembly. See

“Fuser assembly removal” on page 4-6.

Does error clear?

2 Check fuser connector for damage. Replace

if necessary. Does error clear?

3 Turn printer off, and check cable that

connects engine controller board connector FUCN to fuser for proper connection, continuity, and pin shorts. Is cable okay?

4 Replace fuser assembly. See “Fuser

assembly removal” on page 4-6. Does

error clear? Note: Fuser is a customer order supply.

Problem solved. Go to step 2.

Problem solved. Go to step 3.

Go to step 4. Properly connect cable or

replace if damaged. If error clears, problem solved, otherwise go to step 4.

Problem solved. Replace engine controller

board. See “Engine

controller board removal” on page 4-34.

Fuser assembly service check

Step Questions / actions Yes No

1 Check for proper input line voltage. Is line

voltage correct?

2 Remove and reinstall fuser assembly. See

“Fuser assembly removal” on page 4-6.

Does error clear?

Go to step 2. Provide proper line voltage.

Problem solved. Go to step 3.

3 Check fuser connector for damage. Replace

if necessary. Does error clear?

4 Turn printer off, and check cable that

connects engine controller board connector FUCN to fuser for proper connection, continuity, and pin shorts. Is cable okay?

5 Replace fuser assembly. See “Fuser

assembly removal” on page 4-6. Does

error clear? Note: Fuser is a customer-ordered supply.

Problem solved. Go to step 4.

Go to step 5. Properly connect cable or

replace if damaged. If error clears, problem solved, otherwise go to step 5.

Problem solved. Replace LVPS. See “Low

voltage power supply (LVPS) with cage removal” on page 4-40. If

error does not clear, replace engine controller board. See “Engine

controller boar d remov al” on page 4-34.

2-24 Service Manual

Laser unit assembly service check

Step Questions / actions Yes N o

7100-XXX

1 Check LCN connection on laser assembly

LDU board. Is connector properly connected?

2 Check LCN connection on engine controller

board. Is cable properly connected?

3 Check cable that connects engine controller

board LCN and LDU LCN connectors for continuity and shorted pins. Is cable okay?

4 Does error clear? Problem solved. Replace engine controller

Go to step 2. Properly connect LCN

Go to step 3. Properly connect LCN

Replace laser unit assembly. “Upper right

rear cover removal” on page 4-17. Go to step 4.

cable. If error clears, problem solved, otherwise go to step 2.

cable. If error clears, problem solved, otherwise go to step 3.

Replace cable. Go to step

board. See “Engine

controller board remo val” on page 4-34.

HVPS connection service check

Step Questions / actions Yes N o

1 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove shield. Is cable properly connected to BCN1 on the HVPS and the engine controller board HVCN connector?

Go to step 2. Properly connect cable.

Retest printer. If error clears, problem solved, otherwise go to step 2.

2 Turn printer off, and remove items to expose

HVPS. See “High voltage power supply

(HVPS) removal” on page 4-39 for steps.

Check for continuity and pin shorts of cable that connects engine controller board HVCN and HVPS BCN1. Is cable okay? Also ensure that there is no damage to the connectors on both boards.

Replace HVPS. See “High

voltage power suppl y (HVPS) removal” on page 4-39. Retest printer. If

error clears, problem solved, otherwise turn printer off and replace engine controller board. See “Engine controller

board removal” on page 4-34.

Replace cable. Retest printer. If error clears, problem solved, otherwise turn printer off and replace engine controller board. See “Engine controller

board remova l” on page 4-34.

Diagnostic information 2-25

7100-XXX

Toner empty sensor (sender-TPD) service check

Step Questions / actions Yes No

1 Turn printer off. and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Is cable properly connected to engine controller board connector MCN8?

2 Check the following for continuity between

engine controller board MCN8 cable and toner empty sensor (sender-TPD) cable. See “Toner sensor (sender) removal” on

page 4-24 for steps to gain access to

sensor cable. MCN8

pin 1 pin 1 pin 3 pin 2 pin 5 pin 3 Also check for shorted pins. Is cable okay?

3 Replace toner empty sensor (sender-TPD).

See “Toner sensor (sender) removal” on

page 4-24 for steps. Retest printer. Does

error clear?

4 Replace engine controller board. See

“Engine controller board removal” on page 4-34. POR printer. Does error clear?

Toner empty sensor sender

Go to step 2. Properly connect cable.

Retest printer. If error clears, problem solved, otherwise go to step 2.

Go to step 3. Replace cable. Retest

printer. If error clears, problem solved, otherwise go to step 3.

Problem solved. Go to step 4.

Problem solved. Contact higher level

support.

2-26 Service Manual

Toner empty sensor (receiver-TTR) service check

Step Questions / actions Yes No

7100-XXX

1 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Is cable properly connected to engine controller board connector MCN8?

2 Check the following for continuity between

engine controller board MCN8 cable and toner empty sensor (receiver-TTR) cable. See “Toner sensor (receiver) removal”

on page 4-42 for steps to gain access to

sensor cable. MCN8

pin 2 pin 1 pin 4 pin 2 pin 6 pin 3 pin 8 pin 4 pin 9 pin 5 pin 10 pin 6 Also check for shorted pins. Is cable okay?

3 Replace toner empty sensor (receiver-TTR).

See “Toner sensor (receiver) removal”

on page 4-42 for steps. Retest printer.

Does error clear?

Toner empty sensor sender

Go to step 2. Properly connect cable.

Retest printer. If error clears, problem solved, otherwise go to step 2.

Go to step 3. Replace cable. Retest

printer. If error clears, problem solved, otherwise go to step 3.

Problem solved. Go to step 4.

4 Repl ace engine controller board. See

“Engine controller board removal” on page 4-34. POR printer. Does error clear?

Problem solved. Contact higher level

support.

Diagnostic information 2-27

7100-XXX

Lower feed unit (secondary paper assembly) service check

Step Questions / actions Yes No

1 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remov e shield. Is cable properly connected to engine controller board connector MCN6?

2 Remove right cover. See “Right cover

removal” on page 4-13. Check cable that

connects engine controller board connector MCN6 to lower feed unit for continuity and pin shorts. Is cable okay?

3 Replace lower feed unit. See “Secondary

paper feed assembly removal” on page 4-9. Does error clear?

4 Replace engine controller board. See

“Engine controller board removal” on page 4-34. Does error clear?

Go to step 2. Properly connect cable.

Retest printer. If error clears, problem solved, otherwise go to step 2.

Go to step 3. Replace cable.

Problem solved. Go to step 4.

Problem solved. Contact higher level

support.

2-28 Service Manual

Tray empty service check

Step Questions / actions Yes No

7100-XXX

1 Remove paper tray from printer. Press

bottom of spring platform latches located in rear corners of paper tray. This releases spring platform of paper tray. Ensure tray is raising paper after insertion. Is tray working properly?

2 Ensure paper empty sensor flag swings with

ease and is not broken or damaged. Is flag working properly?

3 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Is cable properly connected to engine controller board connector MCN9?

4 Reconnect operator panel. Turn printer on.

Touch negative lead of voltmeter to metal frame to obtain ground. Touch positive lead to engine controller board MCN9 pin 12 to ensure 5 VDC is being supplied to paper empty sensor. Is 5 VDC present?

5 insert empty paper tray into printer. Check

voltage level on MCN9 pin 14. Is 5 VDC present?

Go to step 2. Replace paper tray.

Go to step 3. Replace paper guide (C)

assembly. See “Paper

guide C assembly removal” on page 4-31.

Go to step 4. Properly connect cable.

Go to step 5. Go to step 8.

Go to step 6. Go to step 7.

6 Remove paper tray, fill with paper and

reinsert. Check voltage level on MCN9 pin

14. Is 0 VDC present?

7 Turn pr inter off. Remove paper guide (C)

assembly. See “Paper guide C assembly

removal” on page 4-31. Check cable for

continuity that connects MCN9 pins 12, 13, and 14 to paper empty sensor. Also check for shorted pins. Is cable okay?

8 Check cable continuity between LVPS ACN1

and engine controller board connector POCN. Also check for shorted pins. Is cable okay?

Replace engine controller board. See “Engine

controller board removal” on page 4-34.

Replace paper guide (C) assembly. See “Paper

guide C assembly removal” on page 4-31.

Replace LVPS. See “Low

voltage power supply (LVPS) with cage removal” on page 4-40.

Replace paper guide (C) assembly. See “Paper

guide C assembly removal” on page 4-31.

Replace cable.

Diagnostic information 2-29

7100-XXX

Paper tray missing service check

Step Questions / actions Yes No

1 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Is cable properly connected to engine controller board connector MCN7?

2 Turn printer on, and check for 5 VDC

between MCN7 pin 2 and ground. Is 5 VDC present?

3 Check for cable continuity between LVPS

ACN1 and engine controller board POCN. Is continuity present?

4 With pap er tray removed, take voltage

readings between ground and engine controller board MCN7 pins 4, 6, 8 and 10. Do you read 0 VDC on all the pins?

5 Check cable for continuity between engine

board MCN7 and paper size sensor. Also check for shorted pins. Is cable okay?

Go to step 2. Properly connect cable.

Go to step 4. Go to step 3.

Replace LVPS. See “Low

voltage power supply (LVPS) with cage removal” on page 4-40.

Replace engine controller board. See “Engine

controller board removal” on page 4-34.

Replace paper size sensor. See “Left tray guide

assembly removal” on page 4-42.

Go to step 4.

Go to step 5.

Replace cable by replacing the left tray guide assembly. See “Left tray guide

assembly removal” on page 4-42.

2-30 Service Manual

Toner low/empty service check

Step Questions / actions Yes No

7100-XXX

1 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Is cable properly connected to engine controller board connector MCN8?

2 Reconnect operator panel. Turn printer on.

Touch negative lead of voltmeter to metal frame to obtain ground. Touch positive lead to MCN8 pin 2, 4, 6, or 8 for specific color as dictated by list below:

MCN8 pin2—black(K) pin4—yellow(Y) pin6—magenta(M) pin8—cyan(C)

Slightly remove toner cartridge in question. V o ltmeter should read approximately 4.8 VDC. Continue to slowly slide toner cartridge out of printer while noting voltmeter reading. Voltage should slowly decrease until it reads approximately 0 VDC. Is toner sensor system working properly?

Waste toner bottle service check

Go to step 2. Properly connect cable.

Replace engine controller board. See “Engine

controller board removal” on page 4-34.

Check cable for continuity between engine controller board connector MCN8 and toner sensor system (both sender and receiver). Also check for shorted pins. See

“Toner sensor (sender) removal” on page 4-24

and “Toner sensor

(receiver) removal” on page 4-42 for steps to

expose cable. If cable is okay, replace toner sensor system.

Step Questions / actions Yes No

1 Remove waste toner bottle from printer.

inside waste toner bottle holder, check sensor flag. Does flag work properly, and is it not damaged?

2 Reinstall waste toner bottle. Does error

clear?

3 Replace waste toner bottle holder. See

“Waste toner bottle holder removal” on page 4-22. Does error clear?

Go to step 2. Replace waste toner bottle

holder. See “Waste toner

bottle holder removal” on page 4-22.

Problem solved. Go to step 3.

Problem solved. Replace engine controller

board. See “Engine

controller board remov al” on page 4-34.

Diagnostic information 2-31

7100-XXX

Missing toner cartridge service check

Step Questions / actions Yes No

1 Remove toner cartridge in question. Holding

toner cartridge with developer roller away from you, check toner present sensor actuators located on left rear of toner cartridge. Are actuato rs damaged?

2 In sert toner cartridge, and ensure toner

present sensor flag moves forward. Remov e toner cartridge. Toner present sensor flag should spring forward. Does toner present sensor flag operate correctly?

3 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Is cable properly connected to engine controller board connector MCN2?

4 Reconnect operator panel. Turn printer on.

Touch negative lead of voltmeter to metal frame to obtain ground. Touch positive lead to engine controller board connector MCN2 pin 2 to ensure 5 VDC is being supplied to toner present sensor. Is 5 VDC present?

5 Check voltage level on MCN2 pin 1. Is 5

VDC present?

Replace toner cartridge. Go to step 2.

Go to step 3. Replace toner present

sensor. See “Toner

present sensor removal” on page 4-41.

Go to step 4. Properly connect cable.

Go to step 5. Go to step 8.

Go to step 6. Go to step 7.

6 install toner cartridge. Check voltage level

on MCN2 pin 1. Is 0 VDC present?

7 Turn printer off. Check cable for continuity

that connects MCN2 pins 1, 2, and 3 to toner present sensor. Also check f or shorted pins. Is cable oka y ?

8 Touch positive lead to engine controller

board connector POCN pins 13, 15, and 17 to ensure 5 VDC is being supplied to engine controller board. Is 5 VDC present?

9 Check cable continuity between LVPS

ACN1 and engine controller board connector POCN. Also check for shorted pins. Is cable oka y ?

Replace engine controller board. See “Engine

controller board remo val” on page 4-34.

Replace toner present sensor. See “Toner

present sensor removal” on page 4-41.

Replace engine controller board. See “Engine

controller board remo val” on page 4-34.

Replace LVPS. See “Low

voltage power supply (LVPS) with cage removal” on page 4-40.

Replace toner present sensor. See “Toner

present sensor removal” on page 4-41.

Replace cable.

Go to step 9.

Replace cable.

2-32 Service Manual

Missing photodeveloper cartridge service check

Step Questions / actions Yes No

7100-XXX

1 Check photodeveloper cartridge for proper

installation. Is cartridge installed properly?

2 Check printer contacts (A) and

photodeveloper cartridge contacts (B) for dirt and damage. Are contacts okay?

Go to step 2. install properly.

Replace photodeveloper cartridge. See

“Photodeveloper cartridge removal” on page 4-8.

Note: photodeveloper

cartridge is a customerordered supply.

If problem persists, replace HVPS. See “High voltage

power supply (HVPS) removal” on page 4-39.

Replace photodeveloper cartridge. See

“Photodeveloper cartridge removal” on page 4-8.

Diagnostic information 2-33

7100-XXX

Transfer roller missing service check

Step Questions / actions Yes No

1 Turn printer off, and check transfer roller

contacts. Are contacts present and not damaged?

Go to step 2. If contact A has slipped off

frame, put it back on. If you cannot see it, remove HVPS cage (see “HVPS

cage removal” on page 4-41)and put it back

in place. If B is damaged, replace registration assembly. See

“Registration assembly removal” on page 4-33.

2 Replace engine controller board. See

“Engine controller board removal” on page 4-34. Does error clear?

Problem solved. Replace HVPS. See “High

voltage power suppl y (HVPS) removal” on page 4-39.

2-34 Service Manual

Cover open service check

Step Questions / actions Yes No

7100-XXX

1 Turn printer off, and remove right cover.

See “Right cover removal” on pa ge 4-13. Check all interlock switch (top, rear and front) actuators for proper operation. Are actuators good?

2 Check each interlock switch (top, rear and

front) for proper operation and damage. Listen for switching action. Using an ohmmeter, check switches. When switch is open (cover open), resistance between pin 1 and pin 3 is 0 and pin 1 and 2 is infinite. Closing switch will show 0 resistance between pins 1 and 2 and infinite resistance between pins 1 and 3. Are switches good?

3 Turn printer on. Check for 5 VDC between

front cover interlock switch pin 1 (top pin) and ground. Is 5 VDC present?

Go to step 2. Replace appropriate

actuator: Front cover for front cover

interlock switch. See

“Front cover assembly removal” on page 4-12.

Top cover assembly for top cover interlock switch. See

“Top cover assembly removal” on page 4-10.

Rear cover actuator for rear cover interlock switch. Actuator is contained in parts packet.

Go to step 3. Replace switch in question.

See “Front door interlock

switch with bracket” on page 4-21 for front interloc k

switch, see “Pow er supply

fan removal” on page 4-48 for rear and top

interlock switches.

Go to step 5. Go to step 4.

4 Turn printer off, and check cable for

continuity between LVPS ACN2 pin 1 and cable that connects to front cover interlock switch pin 1. Is cable okay?

5 Check the following cables for continuity:

• Engine controller board MCN4 pin 1 to rear interlock switch pin 3

• Engine controller board MCN4 pin 3 to top interlock switch pin 3

• Top cover interlock switch pin 1 to front cover interlock switch pin 2

• Top cover interlock switch pin 2 to rear cover interlock switch pin 1

• LVPS ACN2 pin 2 to rear cover interlock switch pin 2.

Are any cables defective?

Replace LVPS. See “Low

voltage power suppl y (LVPS) with cage removal” on page 4-40.

Replace cable. Replace engine controller

Replace cable.

board. See “Engine

controller boar d remov al” on page 4-34.

Diagnostic information 2-35

7100-XXX

OPC belt (photodeveloper) cartridge drive service check

Step Questions / ac tions Yes No

1 Check photodeveloper cartridge for proper

installation. Is cartridge installed properly?

2 Check photodeveloper cartridge for

damage. Is cartridge damaged?

3 Check main motor assembly for damage. Is

main motor assembly damaged?

Go to step 2. install properly.

Replace photodeveloper cartridge. See

“Photodeveloper cartridge removal” on page 4-8.

Note: photodeveloper

cartridge is a customerordered supply.

Replace main motor assembly. See “Main

motor assembly removal” on page 4-26.

Go to step 3.

Replace main drive assembly. See “Main drive

gear assembly removal” on page 4-27.

Missing fuser service check

Step Questions / ac tions Yes No

1 Check photodeveloper cartridge for proper

installation. Is cartridge installed properly?

2 Check photodeveloper cartridge for

damage. Is cartridge damaged?

Go to step 2. install properly.

Replace photodeveloper cartridge. See

“Photodeveloper cartridge removal” on page 4-8.

Note: photodeveloper

cartridge is a customerordered supply.

Go to step 3.

3 Check main motor assembly for damage. Is

main motor assembly damaged?

2-36 Service Manual

Replace main motor assembly. See “Main

motor assembly removal” on page 4-26.

Replace main drive assembly. See “Main drive

gear assembly removal” on page 4-27.

Paper size sensing service check

Step Questions / actions Yes No

7100-XXX

1 Turn printer off, and remove engine

controller board shield. See “Engine

controller board removal” on page 4-34

for steps to remove engine controller board shield. Is cable properly connected to engine controller board connector MCN7?

2 Turn printer on, and check for 5 VDC

between MCN7 pin 2 and ground. Is 5 VDC present?

3 Check for cable continuity between LVPS

ACN1 and engine controller board POCN. Is continuity present?

4 If paper tray is removed, set paper tray for

desired paper size, and insert paper tray into printer. Using table below, check for proper paper size sensor action by taking voltage readings between ground and engine controller board MCN7 pins 4, 6, 8 and 10. Is paper size sensor working properly?

5 Check cable for continuity between engine

board MCN7 and paper size sensor. Also check for shorted pins. Is cable okay?

Go to step 2. Properly connect cable.

Go to step 4. Go to step 3.

Replace LVPS. See “Low

voltage power supply (LVPS) with cage removal” on page 4-40.

Replace engine controller board. See “Engine

controller board removal” on page 4-34.

Replace paper size sensor. See “Left tray guide

assembly removal” on page 4-42.

Go to step 4.

Go to step 5.

Replace cable by replacing the left tray guide assembly. See “Left tray guide

assembly removal” on page 4-42.

Paper tray setting MCN7 (all voltages measured from pin to ground)

Standard tray

A4 5 VDC 5 VDC 0 VDC 5 VDC Letter 5 VDC 0 VDC 5 VDC 5 VDC EXE 0 VDC 5 VDC 0 VDC 5 VDC B5J 5 VDC 0 VDC 0 VDC 5 VDC B51 5 VDC 0 VDC 0 VDC 5 VDC #10 0 VDC 0 VDC 0 VDC 5 VDC DL 0 VDC 0 VDC 0 VDC 5 VDC Legal tray 0 VDC 0 VDC 5 VDC 5 VDC

pin 4 pin 6 pin 8 pin 10

Diagnostic information 2-37

7100-XXX

Printer no power service check

Note: If secondary paper feed assembly or duplex unit is installed, disconnect or remove before checking

base printer operation.

Step Questions / actions Yes No

1 Reset printer, and listen for an y activation of

motors and for power supply fan. Look at operator panel to see if anything displays. Do you hear sounds, or does the operator panel display anything?

2 Disconnect and check continuity of power

cord. Is power cord good?

3 Ensure RIP board is properly installed. Is

RIP board installed correctly?

4 Replace RIP board. See “System board

removal” on page 4-36. Does problem

persist?

5 Turn printer off, and check line voltage to

ensure that it is present and correct. Is voltage present and correct?

6 Remove items (see “System board cage

removal” on page 4-38) from left side of

printer to expose power supply bracket. Using an ohmmeter, ensure power switch is good. Is power switch good?

Go to step 2. Go to step 3.

Go to step 3. Replace power cord.

Go to step 4. install RIP board.

Replace engine controller board. See “Engine

controller board removal” on page 4-34.

Go to step 6. inform customer.

Go to step 7. Replace power supply

Problem solved.

bracket. See “Low voltage

power supply (LVPS) with cage removal” on page 4-40 for steps to

remove power supply bracket.

7 Check LVPS ACN1, ACN2, and ACN4 for

proper connection. Are cables properly connected to LVPS?

2-38 Service Manual

Replace LVPS. See “Low

voltage power supply (LVPS) with cage removal” on page 4-40.

Properly connect cables.

Toner feed service check

Step Questions / actions Yes No

7100-XXX

1 Check toner cartridge for damage. Check to

see if toner cartridge moves easily into and out of printer. Is toner cartridge damaged or is there resistance moving in and out of printer?

2 Is developer motor damaged? Replace developer drive

3 Is developer drive assembly damaged? Replace developer drive

Replace toner cartridge. Go to step 2.

Go to step 3.

assembly. See “Developer

drive assembly removal” on page 4-22.

Contact higher level

assembly. See “Developer

drive assembly removal” on page 4-22.

technical support.

Waste toner feed service check

Step Questions / actions Yes No

1 Is transfer belt unit cleaning roller properly

installed?

2 Check cleaning roller clutch gear (located

inside printer) for damage. Is cleaning roller clutch damaged?

Go to step 2. Properly install cleaning

roller.

Replace cleaning roller clutch.

Go to step 3.

3 Check waste toner bottle for overflow. Is

waste toner overflowing?

4 Check waste toner auger for damage. Is

waste toner auger damaged?

5 Check waste toner agitator for damage. Is

waste toner agitator damaged?

6 inspect waste toner feeder and opening in

bottom of printer. Is waste toner feeder damaged?

Go to “Waste toner bottle

service check” on page 2-31.

Replace waste toner auger. See “Waste toner auger

removal” on page 4-47.

Replace waste toner agitator. See “Waste toner

agitator removal” on page 4-47.

Replace waste toner feeder . See “Waste toner feeder

removal” on page 4-28.

Go to step 4.

Go to step 5.

Go to step 6.

Problem solved.

Diagnostic information 2-39

7100-XXX

Operator panel service check

Step Questions / actions Yes No

1 Is the operator panel cable properly

connected to the op panel?

2 Is the op panel cable properly connected to

the RIP board connector J-PNL1?

3 Check the op panel cable continuity . Is there

continuity?

4 Check Voltages on J-PNL1, located on the

RIP card. Pin 1 voltage should measure 5V. Is it correct?

Go to step 2. Properly connect the cable

to the op panel.

Go to step 3. Properly connect the cable

to J-PNL1.

Go to step 4. Replace the flatbed unit.

See “Flatbed assembly

removal” on page 4-49.

Replace the operator panel. See “Operator panel

removal” on page 4-57.

Replace the system board. See “System board

removal” on page 4-36.

USB service check

Step Questions / actions Yes No

1 Is the USB cable properly connected to the

MFP and host PC?

2 Try a different USB cable. Does this fix the

issue?

3 Connect a different device to the USB cable.

Did the host PC see the device?

Go to step 2. Properly connect the cable

at both ends.

Issue fixed. Go to step 3.

Replace the RIP/system board.See “System board

removal” on page 4-36.

There is an issue with the host machine.

Network service check

Step Questions / actions Yes No

1 Ping the MFP using the address on the MFP

op panel. Is it responding?

2 Is the ethernet cable properly connected to

the network card RJ-45 connector?

3 Check to see if DHCP is being used on the

network. Is DHCP used?

4 Does the MFP IP address match the ports

IP address on the driver?

5 Have the network admin try a new network

cable to the MFP. Did this fix the problem?

Go to step 3 Go to step 2.

Go to step 3. Properly connect the cable

to the RJ-45 jack.

Go to step 4. Go to step 5.

Go to step 5. Have the network admin

create a port on the host PC matching the IP address on the MFP. Assign the new port to the driver.

Problem resolved. Replace the system board.

See “System board

removal” on page 4-36.

2-40 Service Manual

Scanner / Copy / Fax service checks

Black page copy service check

Step Questions / actions Yes No

7100-XXX

1 Print a menu page, or a page from the host.

Is the page black?

2 Is the CCD ribbon cable properly connected

to J-CCD on the system board?

3 Check for +3.3VDC on pins 12 and 16 on

connector J-CCD. Pins 10 and 20 are +5VDC. Pin 8 is +12VDC. Are the voltages present?

See “High voltage power

supply (HVPS) service check” on page 2-23

Go to step 3. Properly connect the ribbon

Replace the flatbed unit. See “Flatbed assembly

removal” on page 4-49.

Go to step 2.

cable to J-CCD. Replace the system board.

See “System board

removal” on page 4-36.

Flatbed service check

Step Questions / actions Yes No

1 Check to see if the flatbed is locked. Is it

locked?

2 Ensure that the flatbed motor cable (JFB1)

is connected. Is the cable connected?

3 Check pin 1 in J-FB1 for voltage. The

voltage is only present when a copy job is running. The voltage should measure 5V. Is voltage present?

Unlock the flatbed. Go to step 2.

Go to step 3. Properly connect the cable.

Replace the flatbed unit. See “Flatbed assembly

removal” on page 4-49.

Replace the system board. See “System board

removal” on page 4-36.

ADF streak service check

Step Questions / actions Yes No

1 Do streaks appear on the middle of

scans when using the ADF?

Clean the ADF glass on the flatbed using a lint-free cloth. Also, clean the separator roll and pad with a damp cloth.

No issue to fix.

Diagnostic information 2-41

7100-XXX

ADF paper feed service check

Step Questions / actions Yes No

1 If the ADF is multi-feeding, check for dirt on

the ADF separator pad and ADF separator 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.

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 leading edge of the paper to

ensure the paper is not curled or bent in a

way that would keep it from contacting the

paper sensor actuator. Is the paper

damaged? 6 I s there dirt in the sensors, or is the paper

present actuator stuck?

7 Are the sensor actuators on the ADF

mechanism cover damaged? 8 Is the ADF connector properly connected to

J-ADF1 on the system board?

Clean them with a lint free cloth and isopropyl alcohol.

Go to step 3. Set the paper guides so

Properly close the top cover.

Bad media. Go to step 6.

Clean the sensors, or remove debis from the actuators.

Replace the ADF mechanism cover.

Go to step 9. Properly connect the cable

Replace the separator pad and ADF pick roll.

they contact the edges of the paper.

If the paper is jamming in the ADF, go to step 6

Go to step 7.

Go to step 8.

to the system board.

9 inspect the connections on the ADF relay

card in the ADF. Are all the connections

properly connected?

10 Check the ADF cable for continuity. Is there

continuity?

11 Check for signals or voltages from J-ADF.

The voltage will only be present on pin 1

when a copy job is run. Pin one on

connector J-ADF1 should measure + 5v. Are

there signals or voltages present?

Go to step 10. Secure all the connections.

Go to step 11. Replace the ADF cable.

Replace the ADF unit. See

“ADF unit removal” on page 4-53.

Replace the system board. See “System board

removal” on page 4-36.

2-42 Service Manual

Modem / fax card service check

Step Questions / actions Yes No

7100-XXX

1 Is the phone line properly connected to the

modem card and the wall jack?

2 Is the modem card cable properly

connected to the system board at J-FAX-1 and the modem card?

3 Check the modem card cable for continuity.

Is there continuity?

4 Check the voltages from connector J-

F AX1on the RIP card. Check pins 1 and 2 for +3.3V. Pins 24, 27 and 28 are grounds. Are there signals or voltages present?

Go to step 2. Properly connect the phone

line to the modem card and wall jack.

Go to step 3. Properly connect the

modem card cable to the modem card and system board.

Go to step 4. Replace the modem card

cable.

Replace the modem card. See “Modem card

removal” on page 4-45.

Replace the system board. See “System board

removal” on page 4-36.

Diagnostic information 2-43

7100-XXX

Paper feed service checks

Printer paper feed service check

Problem area Action

1 Check for recommended paper Ensure paper being used is recommended.

Ensure paper is stored in an area free from high humidity. Note: Disconnect secondary paper assembly, if installed, to help

isolate a paper transport problem.

2 Paper tray Ensure paper tray is not damaged.

Check for paper caught behind tray in pickup transport roll. Replace any damaged parts.

3 • Paper feed roller

• Separator pad

4 • Registration roller

• Transfer roller

5 Transfer belt unit Ensure transfer unit is not damaged and is free of foreign material.

6 Transfer belt unit cleaning roller Ensure no paper is jammed in cleaning roller.

7 Fuser assembly Ensure fuser assembly is not damaged or dirty.

8 • Paper exit assembly

• Gears

Check paper feed roller and separator pad for wear or damage. See

“Paper feed roller removal” on page 4-32.

Replace any damaged parts. Check registration roller for damage or binds, and replace if

necessary. See “Registration assembly removal” on page 4-33. Check transfer roller for damage, and replace if necessary. See

“Transfer roller removal” on page 4-6.

Note: Do not touch transfer belt with your hands.

Ensure cleaning roller is not damaged. Replace cleaning roller if necessary.

Ensure fuser assembly guides and gears are not broken and are free of paper.

Note: Fuser assembly is a customer-ordered supply. Check rear cover assembly for damage.

Ensure paper exit roller located in paper exit assembly is not damaged.

Ensure paper exit gears and bearings are good. Ensure paper guides are not bent or dirty. Clean or replace parts if necessary.

2-44 Service Manual

Print quality service checks

Background service check

Background is smeared due to toner spread.

Problem area Action

1 Toner cartridge Too small charging amount in the development process.

7100-XXX

2 Check developer high voltage contact points. insufficient contact of developer roller's primar y or secondary

3 Photodeveloper (OPC) cartridge Photodeveloper cartridge has reached life or is failing.

4 High voltage po wer supply (HVPS) HVPS has failed. Replace HVPS. See “High voltage power

high voltage contact points. Ensure primary and secondary contact points are free from contamination and toner debris.

Check toner cartridge developer roller bias pole. If contaminated, clean it. If damaged or deformed, replace toner cartridge.

Replace photodeveloper cartridge. See “Photodeveloper

cartridge removal” on page 4-8.

Note: Photodeveloper cartridge is a customer-ordered

supply.

supply (HVPS) removal” on page 4-39.

Diagnostic information 2-45

7100-XXX

Back stain service check

Backside of paper is stained.

Problem area Action

1 Fuser assembly • Fuser roller and back-up roller are stained.

• Fusing offset error occurred.

Replace fuser assembly. See “Fuser assembly removal”

on page 4-6.

Note: Fuser assembly is a customer-ordered supply.

2 Transfer roller Transfer roller is stained. Replace transfer roller. See

“Transfer roller removal” on page 4-6.

2-46 Service Manual

7100-XXX

Banding service check

A banding line appears in horizontal direction.

Problem area Action

1 Photodeveloper (OPC) cartridge Transfer failure due to uneven rotational speed caused by a

shock which occurs when the seam of the OPC belt passes over the cleaning blade.

Replace photodeveloper cartridge. See “Photodeveloper

cartridge removal” on page 4-8.

2 Toner cartridge OPC belt and transfer belt fail to maintain regular and proper

rotation due to impact created during retract of toner cartridge. Replace toner cartridge.

Diagnostic information 2-47

7100-XXX

Black line service check

A fine black line appears in printer image.

Problem area Action

1 Toner cartridge Toner cartridge blade is deformed.

Replace toner cartr idge.

2 Photodeveloper (OPC) cartridge OPC belt surface is damaged. Replace photodeveloper

3 Debris Foreign particles (paper dust, and so on) have adhered to

cartridge. See “Photodeveloper cartridge removal” on

page 4-8.

perimeter parts of OPC belt and transfer unit belt. Clean perimeter of mounting area of OPC belt and transfer belt.

2-48 Service Manual

7100-XXX

Color misregistration service check

Color misregistration between tw o colors.

Problem area Action

1 Transfer roller and transfer belt cleaning roller Transfer belt fails to maintain regular and proper rotation due

to impact caused when transfer roller or transfer belt cleaning roller contacts transfer belt.

Ensure transfer roller and transfer belt cleaning roller are properly installed.

2 Toner cartridge Developer cartridge OPC belt fails to maintain regular and

3 Photodeveloper cartridge OPC belt is off track.

4 Transfer belt unit Transfer belt is off track.

proper rotation due to impact caused when toner car tridge contacts OPC belt.

Ensure toner cartridge is properly installed.

Replace photodeveloper cartridge. See “Photodeveloper

cartridge removal” on page 4-8.

Note: Photodeveloper cartridge is a customer order supply.

Replace transfer belt unit. See “Transfer belt unit removal”

on page 4-5.

Diagnostic information 2-49

7100-XXX

insufficient fusing service check

Printed image is partially missing.

Problem area Action

1 Fuser tension release lever Fuser tension release lever is open. Check fuser, and remove

shipping pieces if still installed. Close release lever.

2 Driver media settings Driver media setting is wrong. Ensure proper media setting is

3 Non-recommended paper Non recommended paper is being used. Replace paper with

4 Fuser Replace failed fuser. See “Fuser assembly removal” on

selected for specific media in use.

insufficient gloss service check

Gloss on paper is not sufficient.

Problem area Action

1 Driver media settings Driver media setting is wrong. Ensure proper media setting is

selected for specific media in use.

2 Fuser Fuser roller is deteriorated.

Fuser temperature is not properly controlled. Replace fuser. See “Fuser assembly removal” on page 4-6.

Note: The fuser is a customer order supply.

Diagnostic information 2-51

7100-XXX

Jitter service check

Uneven optical density appears periodically in horizontal direction.

Problem area Action

1 Photodeveloper cartridge Replace faulty photodeveloper cartridge. See

“Photodeveloper cartridge removal” on page 4-8.

Note: Photodeveloper cartridge is a customer order supply.

2 Main motor assembly • Irregular rota tion of main motor assembly

• Main motor assembly gear unit failure

• Variation of OPC belt running speed due to failing main motor assembly

Replace main motor assembly. See “Main motor assembly

removal” on page 4-26.

3 Developer drive assembly Replace faulty developer drive assembly. See “Developer

drive assembly removal” on page 4-22.

2-52 Service Manual

Missing image at edge service check

Image has missing or peeling toner at edge.

Problem area Action

7100-XXX

1 Toner cartridge Too small a toner mass amount and charging amount in the

2 Photodeveloper cartridge OPC belt is deformed and wavy.

development process. Replace toner cartridge.

Replace photodeveloper cartridge. See “Photodeveloper

cartridge removal” on page 4-8.

Note: Photodeveloper cartridge is a customer order supply.

Diagnostic information 2-53

7100-XXX

Mixed color image service check

Mixed color image appears.

Problem area Action

1 Toner cartridge Ensure toner cartridge moves in and out of printer without a lot

2 Transfer roller clutch Replace transfer roller clutch. See “Clutch removal” on

3 Transfer belt unit cleaning roller clutch Replace transfer belt unit cleaning roller clutch. See

of resistance. Compare toner cartridge in question with one of the other known working cartridges.

Replace toner cartr idge if defective.

page 4-27.

“Cleaning roller clutch removal” on page 4-25.

2-54 Service Manual

Mottle service check

Variation of optical density is found in image.

Problem area Action

1 Rear cover assembly Rear cover assembly is not fixed in place.

Open rear cover assembly, and close properly.

2 Transfer roller Transfer roller is not properly installed.

Remove and reinstall transfer roller. See “Transfer roller

removal” on page 4-6.

7100-XXX

3 Paper Replace deformed paper. 4 Toner cartridge Replace defective toner cartridge. 5 HVPS Replace faulty HVPS. See “High voltage power supply

(HVPS) removal” on page 4-39.

Diagnostic information 2-55

7100-XXX

Residual image service check

Image of preceding page appears on every other page.

Problem area Action

1 Transfer unit cleaning roller Cleaning roller is not installed properly. Remove and reinstall.

2 HVPS Replace faulty HVPS. See “High voltage power supply

Ensure left side of cleaning roller is making good contact with HVPS contact.

If error continues to occur after reinstallation, replace cleaning roller. See “Transfer belt cleaning roller removal” on

page 4-4.

(HVPS) removal” on page 4-39.

2-56 Service Manual

Ribbing service check

Light print occurs in right or left side of image.

Problem area Action

1 Printer is not level Table printer is sitting on is slightly tilted.

Tilt should be less than 1/2 inch. Confirm the printer table is large enough and the printer is

level.

2 Toner cartridge insufficient amount of toner in the toner cartridge.

Shake the toner cartridge horizontally several times to level the toner.

7100-XXX

3 Toner car tridge Toner in the toner cartridge is not level and collects on one

4 Rear cover assembly Open rear cover assembly, and close properly. 5 Photodeveloper cartridge Photodeveloper OPC belt is off rack and becomes deformed

side. Shake the toner cartridge horizontally several times to level

the toner. If problem persists, replace toner cartridge.

during operation. Replace photodeveloper cartridge. See “Photodeveloper

cartridge removal” on page 4-8.

Note: Photodeveloper cartridge is a customer order supply.

Diagnostic information 2-57

7100-XXX

Smear service check

The entire image appears smudged.

Problem area Action

1 Photodeveloper cartridge (OPC belt) and

transfer belt

This print quality issue is usually accompanied by a paper jam.

Remove the photodeveloper cartridge, and check for a piece of paper on the rear side of the photodeveloper cartridge. Remove the piece of paper from the photodeveloper.

Note: This occurs mostly with A5 and B5 size media.

2-58 Service Manual

Toner drop service check

A toner spot stain on paper is caused by ambient toner within printer engine.

Problem area Action

7100-XXX

1 Waste toner feed system

• Waste toner auger

• Waste toner feeder

2 Transfer unit cleaning roller Cleaning roller is faulty.

3 Toner cartridge Replace faulty toner cartridge.

Toner drops on the transfer drum due to a breakdown of the waste toner feed system.

• Waste toner auger mylar is damaged. Examine and replace if defective. See “W aste toner auger removal” on

page 4-47.

• Waste toner is not properly collected by waste toner feeder. Check to ensure that waste toner feeder is not compacted. If so, replace waste toner feeder . See “W aste toner feeder

removal” on page 4-28.

• Check for waste toner in printer. If found, clean and vacuum printer.

Remove transfer belt unit (see “Transfer belt unit removal”

on page 4-5). Replace cleaning roller. See “Transfer belt cleaning roller removal” on page 4-4. Prior to installation of

new cleaning roller, thoroughly clean cleaning roller installation area.

Check for waste toner in printer. If found, clean and vacuum printer.

Diagnostic information 2-59

7100-XXX

Vertical line service check

A vertical line appears in printed image.

Problem area Action

1 Photodeveloper cartridge (OPC belt) and

transfer belt

2 Transfer unit cleaning roller and waste toner

auger

Foreign particles (dust and so on) adhere to parts located around photodeveloper cartridge and transfer belt unit which consequently contact toner image on transfer belt unit.

Remove and clean photodeveloper cartridge, transfer belt unit, and adjacent areas.

Cleaning roller and waste toner auger area are dirty. Remove cleaning roller and clean waste toner auger and area

around it. Reinstall cleaning roller.

2-60 Service Manual

Vertical staggering image service check

Printed image staggers in vertical direction.

Problem area Action

1 Printer vibration Check for printer vibrations or shock to printer.

7100-XXX

2 Laser unit assembly (printhead) Optical unit failure caused by vibration from scanner motor

rotation. Replace laser unit assembly. See “Upper right rear cover

removal” on page 4-17.

Diagnostic information 2-61

7100-XXX

Vertical white band service check

White band appears in vertical direction of printed image.

Problem area Action

1 Toner cartridge Replace faulty toner cartridge. 2 Photodeveloper cartridge Replace faulty photodeveloper cartridge. See

“Photodeveloper cartridge removal” on page 4-8.

3 Transfer belt unit Replace faulty transfer belt unit. See “Transfer belt unit

removal” on page 4-5.

2-62 Service Manual

Lexmark X500n, X502n Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Notices and safety information

Laser notice

Laser

Avis relatif à l’utilisation de laser

Avvertenze sui prodotti laser

Avisos sobre el láser

Declaração sobre Laser

Laserinformatie

Lasermeddelelse

Laserilmoitus

Huomautus laserlaitteesta

Laser-notis

Laser-melding

Avís sobre el Làser

Consignes de sécurité

Norme di sicurezza

Sicherheitshinweise

Pautas de Segur i dad

Informações de Segurança

Informació de Seguretat

1. General information

Models

MFP Specifications

General device technical specifications

Print engine specifications

Scan specifications

Copy specifications

Fax specifications

Media guidelines

Maintenance approach

Standard inspection and cleaning procedure

Serial number

Tools required for service

Acronyms

2. Diagnostic information

Start

Understanding the operator panel

Service error codes

User status messages

User attendance messages

Symptom tables

MFP symptom table

Print quality symptom table

Printer service checks

Main motor service check

CPU fan service check

Developer drive assembly service check

Transfer belt unit service check

Transfer roller clutch service check

Transfer belt cleaning roller clutch service check

Paper feed clutch service check

Registration clutch service check

OPC belt marker sensor service check

Erase lamp service check

Power supply fan service check

Fuser fan service check

High voltage power supply (HVPS) service check

Low voltage power supply (LVPS) service check

Fuser thermistor service check

Fuser assembly service check

Laser unit assembly service check

HVPS connection service check

Toner empty sensor (sender-TPD) service check

Toner empty sensor (receiver-TTR) service check

Lower feed unit (secondary paper assembly) service check

Tray empty service check

Paper tray missing service check

Toner low/empty service check

Waste toner bottle service check

Missing toner cartridge service check

Missing photodeveloper cartridge service check

Transfer roller missing service check

Cover open service check

OPC belt (photodeveloper) cartridge drive service check

Missing fuser service check