Lexmark X543, X544, X546 Service Manual

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Page 1

• Table of contents

• Start diagnostics

Edition 10-

Lexmark™ X543, X544, X546

7525-xxx

29-09

• Safety and notices

•Trademarks

• Index

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

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Edition: October 29, 2009

The following paragraph does not apply to any country where such provisions are inconsistent with local law:

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

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

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

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

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

Optra Forms is a trademark of Lexmark International, Inc. PostScript® is a registered trademark of Adobe Systems Incorporated. PCL® is a registered trademark of the Hewlett-Packard Company. All other trademarks are the property of their respective owners.

UNITED STATES GOVERNMENT RIGHTS

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

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P/N 12G9825

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Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Lithium warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

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

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

Options and features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Print quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Connectivity (network support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Data streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Power and electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Environment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Media handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Input and output sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Duplex capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Media input size specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Media input type specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Media output size and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

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

Paper characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Unacceptable paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Selecting paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Selecting preprinted forms and letterhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Storing paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Using recycled paper and other office papers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Digital imaging specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

ADF Scan speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

ADF Document handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Resolution and color depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Flatbed document specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Flatbed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Scanner operating environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Storage environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Scan and copy specific specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Scan Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Output resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Duplex scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Scan file output formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Supported compressions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Supported scan destinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Multiple copies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Reduce / Enlarge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Table of contents iii

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Fax specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Phone network connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Fax resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Miscellaneous FAX specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-18

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-20

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

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

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

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Scan / fax / copy symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Error codes and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

User status and attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Paper Jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Service error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15

Fax error log codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

90x.xx error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

925.01—Fan error service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

950.xx NVRAM failure service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Autocompensator mechanism service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Bin full sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

Dead printer service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Duplex/manual feed sensor (S1) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Front door sensor or switches service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

Fuser exit sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

Input sensor (S2) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

Main drive gear assembly (EP drive) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

One or more operator panel buttons fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

Operator panel display blank, five beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Operator panel display blank, printer beeps five times and pauses . . . . . . . . . . . . . . . . . . . . . . 2-43

Operator panel displays all diamonds, no beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Operator panel displays all diamonds, five beeps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Operator panel display is dim and unchanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Op panel USB cable service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

USB service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45

Networking service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

Print quality—background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

Print quality—blank page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Print quality—blurred or fuzzy print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Print quality—half-color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Print quality—horizontal banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Print quality—horizontal line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

Print quality—insufficient fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

Print quality—missing image at edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

Print quality—mottle (2–5mm speckles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Print quality—narrow vertical line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Print quality—random marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

Print quality—residual image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Print quality—solid color page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Print quality—vertical banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

thead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

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Toner meter cycle (TMC) card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Toner sensors (Y, C, M, K) on TMC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Tray (x) sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Option trays 2 and 3 service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61

840.xx service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Black or blank page copy service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

CCD service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Flatbed motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65

Flatbed home position service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66

ADF cover open service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

ADF streak service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

ADF paper jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68

ADF feed errors service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69

ADF Duplex service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70

Modem / fax card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

Fax transmission service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

Fax reception service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74

Escalating a fax issue to second-level support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

User operator panel, menus and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

Understanding the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

Operator panel buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78

Menu map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79

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

Menu key combinations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics Menu (Diag Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Diagnostics menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Quick test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Factory Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Factory Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Miscellaneous Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Motor Detect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Input source tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Print quality test pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

CACHE Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Quick Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Left Margin (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Top Margin (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Input Tray tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

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Page Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

ITU Barcode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Enable Edge to Edge Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Reset Fuser Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

EP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Fuser Temp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

DC Charge Adjust, Deve Bias Adj, Transfer Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

TPS Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Right or Left TPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Reset Color Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Cal Ref Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Main Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24

Scanner Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

ASIC Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

EXIT Diags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

USB Scan to Local . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Prt Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Color Trapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-32

Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Factory defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-33

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Min Copy Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Format Fax Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Auto Color Adj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

ADF Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

FB Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Scanner Manual Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35

To manually register a Duplex ADF, perform the following steps: . . . . . . . . . . . . . . . . . . . . . . .3-35

To manually register the flatbed, perform the following steps: . . . . . . . . . . . . . . . . . . . . . . . . . .3-36

Disable Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Pel Blurring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

xit

SE Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

Print SE Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Code Revision Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

MAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

NVRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38

NPAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

. . . . . . . . . . .3-37

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TCP/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Avoiding jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Understanding jam numbers and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

200 paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

201 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

202 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

230 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

235 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

24x paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

250 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

29x ADF paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

291.xx ADF paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Updating printer firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

There are three options to update firmware on your printer. The instructions for all three options

are listed below. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Using the host computer to update the firmware over USB . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Updating the firmware using a USB thumb drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

Updating the firmware using a networked computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Using FTP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Using the printer’s internal Web server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Print engine theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Electrophotographic Process (EP Process) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

MFP electrophotographic process basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57

Step 1: Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Step 2: Expose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Step 3: Develop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Step 4a: First transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Step 4b: Second transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

Step 5: Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Step 6: Clean/Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Paper path, transport components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Paper path Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66

Transport components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Duplexing (models with duplex support only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

Scanner theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Duplex ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69

Color theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

What is RGB color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

What is CMYK color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

How is color specified in a document to be printed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

How does the printer know what color to print? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Should I use PostScript or PCL emulation? What settings produce the best color? . . . . . . . . . 3-71

Why doesn't the printed color match the color I see on the computer screen? . . . . . . . . . . . . 3-71

The printed page appears tinted. Can I adjust the color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

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

color? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

What is manual color correction? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72

How can I match a particular color (such as a corporate logo)? . . . . . . . . . . . . . . . . . . . . . . . . 3-73

What are detailed Color Samples and how do I access them? . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

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

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

Testing generic FRUs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Print engine removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Front cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Front middle cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Table of contents vii

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

Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Rear shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

AIO back cable cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Autocompensator mechanism (ACM)—standard tray removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Bin full sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Narrow media sensor flag removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Duplex reference edge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Duplex sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

Fuser assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Fuser drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

Fuser exit sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29

High-voltage power supply (HVPS) assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

High voltage power supply (HVPS) with no spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

High-voltage power supply (HVPS) with spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33

Image transfer unit (ITU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

Imaging unit (IU) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

Developer unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42

Low-voltage power supply (LVPS) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Lower frame removal, right and left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Left lower frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Right lower frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48

Main drive gear assembly with motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53

Pick tires removal—integrated 250-sheet media tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55

Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-56

Imaging unit (IU) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57

Toner cartridge contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59

Toner meter cycle (TMC) card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-61

Toner density sensor (TPS)—left and right removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Tray present sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

USB connector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67

Waste toner bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67

Waste toner bottle contact block removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Wireless network antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

Wireless network card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-71

Scanner component removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72

Flatbed removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72

Preparing and installing the new flatbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-78

Flatbed pivot link removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-81

Duplex ADF rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-82

Duplex ADF removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-83

Simplex ADF rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-84

Simplex ADF removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-84

ADF input tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-84

ADF cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-85

ADF separator pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87

ADF separator roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-88

Bezel cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-89

Redrive unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-91

Cover scanner left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-92

Cover scanner right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93

AIO release lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96

AIO toner cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97

Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-98

Op panel bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-100

. . . . . . . . .4-95

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Op panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101

Logo cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101

Fax card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102

Fax interface cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102

Output bin tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103

Bin full flag removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103

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

Exterior views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Interior view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Printer boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Toner meter card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Toner meter card connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Wireless card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

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

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

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

Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

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

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

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 2: Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 3: Paperpath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 4: Electronics 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 5: Electronics 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Assembly 6: Media drawers and trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 7: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

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

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

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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.

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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’imprimante et son système laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

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

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.

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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 normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

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

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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 person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.

Laser-melding

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

CAUTION

This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations.

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.

•This product contains mercury in the lamp (<5mg Hg). Disposal of mercury may be regulated due to

environmental considerations. For disposal or recycling information, contact your local authorities or the Electronic Industries Alliance: www.eiae.org.

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Consignes de sécurité

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

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

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

maintenance qualifié.

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

d'entretien qualifié devra prendre toutes les précautions nécessaires.

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

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

Norme di sicurezza

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

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

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

assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

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

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

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

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Sicherheitshinweise

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

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

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

Wartungsfachmann bestimmt.

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

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

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

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

Pautas de Seguridad

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

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

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

cualificado de mantenimiento.

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

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

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

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

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Informações de Segurança

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

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

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

devem ser utilizadas por outras pessoas.

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

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

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

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

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Informació de Seguretat

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

específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades.

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

destinada a ningú que no ho sigui.

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

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

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

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

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Preface

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.

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

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

There are several types of caution statements:

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1. General information

The Lexmark™ X54x series are color laser MFPs that combine print, scan, copy, and fax functions. The X54x series are the ideal MFPs for presentations, business graphics, line art, and text. They use laser diode electrophotographic technology 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. The X546 can also support a 550 sheet option while the 650 sheet duo drawer is attached.

Models

The Lexmark X54x series MFPs are available in the following models:

Model Configuration Machine type / model

X543dn Print, copy, simplex scan, network 7525-131

X543dn Print, copy, simplex scan, network. DBCS op panel 7525-133

X543dn Print, copy, simplex scan, network

X544n Print

, copy, duplex scan, network, fax 7525-356

, copy, duplex scan, network 7525-352

7525-138

7525-xxx

X544dn Print, copy, duplex scan, network, fax 7525-336

X544dn Print, copy, duplex scan, network 7525-332

X544dn Print, copy, duplex scan, network, fax. DBCS op panel. 7525-337

X544dn Print, copy, duplex scan, network. DBCS op panel 7525-333

X544dw Print, copy, duplex scan, network

X544dtn Print, copy, duplex scan, network, fax. 7525-336 (bundled w/650-sheet

X544dtn Print, copy, duplex scan, network. 7525-332 (bundled w/650-sheet

X544dtn Print, copy, duplex scan, network, fax, DBCS op panel 7525-337 (bundled w/650-sheet

X544dtn Print, copy, duplex scan, network, DBCS op panel 7525-333 (bundled w/650-sheet

X546dtn Print, copy, duplex scan, network 7525-396 (bundled w/550-sheet

, fax 7525-386

, fax, DBCS op panel 7525-387

, DBCS op panel 7525-383

7525-382

optional tray)

X546dtn Print, copy, duplex scan, network, DBCS op panel 7525-397 (bundled w/550-sheet

optional tray)

1. Wireless network

2. Simplex printing only

General information 1-1

Page 24

7525-xxx

✔—Supported ✘—Not supported

Options and features

Certain options are available on selected printer models only.

Available options include:

• 650-Sheet Duo Drawer—a 550-sheet drawer with a 100-sheet multipurpose feeder (MP Feeder).

• 550- Sheet Drawer - X546 only.

• Additional memory—One 128, 256, or 512MB memory card may be added.

• Flash memory card—One 64MB may be added.

• Font cards—One language card can be added.

Memory

Lexmark X543

Memory

Optional slots One slot

Standard DIMM sizes Optional (DDR1) 128MB, 256MB, and 512MB 256MB, 512MB Maximum printer memory Flash memory 64 MB

Option Slots (single slot is available or either font or flash memory card)

Font card support 1 font card Optional user flash memory

card sizes

Connections

USB 2.0 High Speed

Ethernet 10/100 BaseTx

USB-A (allows direct USB printing using approved USB flash memory device)

Pict Bridge (allows printing photos directly from a compatible camera)

128MB 256MB

640MB

0MB 64MB 64MB 64 MB

✔✔

✘✔

✘✔(Only on FAX

Lexmark X544n,

X544dn, X544dtn

equipped

machines)

Lexmark

X544dw

Lexmark

X546dtn

✔ ✔

✔(Only on FAX

equipped

machines)

✔(Only on FAX

equipped

machines)

1-2 Service Manual

Wireless standard 802.11 b/g/n

Dual Inline Memory Module. An optional memory card that can be plugged into an available memory slot.

The X546 slot is filled with a 128 mb DIMM.

The maximum usable DDRSDRAM is standard (soldered) plus 512MB.

✘

✔ ✔

Page 25

Print quality

✔—Supported ✘—Not supported

During the life of the printer, components are subject to wear based on usage. Printers continuously operating at or near the maximum duty cycle may require service for replacement of these components to ensure highquality printing and good performance throughout the life of the printer. Replacement is recommended every 60,000 pages for the fuser and 60,000 pages for the ITU. The fuser and ITU replacement should be determined by checking the last sheet of the Menu Settings Page. Either OK or Replace appears.

To print a Menu Settings page:

1. Press Menu ( ) on the operator panel.

2. Select Reports from the Admin Menu, and press Select ().

3. Select Menu Settings, and press Select ().

Replacement is recommended every 30,000 pages for the imaging unit.

• 4800C Q (default) full printer speed

• 1200 dpi (reduced printer speed) is supported in PS and PCL only

Connectivity (network support)

Network protocol

Lexmark X543

Lexmark X544n, X544dn, X544dtn

Lexmark X544dw

7525-xxx

Lexmark X546dtn

Standard Ethernet 10/100 Base T

Standard USB-B (Full speed) device port

USB-A host ports

(In front, low/full speed) This port only supports the following flash drives and file types:

Supported flash drives: Lexar Jump Drive 2.0 Pro (256/512 MB/1G size) or SanDisk Cruzer Mini (256/ 512 MB/1 G size)

Supported file types: .pdf, .gif, .jpeg, .jpg,.bmp, .p ng, .tiff, .tif, .pcx, .dcx

802.11n Wireless Network card

Manufacturing installs the wireless card during the fabrication process. A wireless card CANNOT be installed post-manufacturing.

USB direct drive

✔✔ ✔ ✔

✘✔ ✔ ✔

✘✘ ✔ ✘

Scan and

print (Select

formats)

Scan and print

(Select

formats)

Scan and print

(Select

formats)

Scan and print

(Select

formats)

General information 1-3

Page 26

7525-xxx

✔—Supported ✘—Not supported

Operating modes

Mode Description

Normal Factory default Quiet Designed for customers where noise levels are a very important

Eco-Mode (Off is default): Designed for customers where the environment is a key factor.

Data streams

factor.

• Print quality is maintained at factory default level.

• Speed is reduced.

There are three options; Energy, Paper, and Energy/Paper.

• Paper • Duplex is on if Energy/Paper or Paper is selected (duplex

models only) (can be overwritten by the driver).

• Energy • Print quality is maintained.

• Power Saver is set to one minute.

• Fuser standby is off.

• The operator panel back light is off.

• Power supply energy consumption is reduced.

• Energy + Paper All of the above.

Data streams Lexmark X543

PCL 6 emulation

PostScript Level III emulation

Version 3011 of the Adobe definition of PostScript 3 is supported.

PDF

Supports version 1.6

PPDS

By default, the PPDS interpreter is inactive. A user can activate the data stream by PJL or by the PPDS Emulation setting in the Configuration Menu

Pict Bridge

Directimage

Devices that support Directimage support all of the following graphics formats: TIFF, TIF, JPEG, JPG, GIF, PNG, BMP, PCX, and DCX.

✔✔✔ ✔

✘✔✔✔

Lexmark X544n, X544dn, X544dtn

Lexmark X544dw

Lexmark X546dtn

1-4 Service Manual

Host-Based Printing (HBP)/ Graphics Device Interface (GDI)

Version 3 (color) uses PCL XL.

✔✔✔ ✔

Page 27

Dimensions

Models Height Width Depth Weight

Lexmark X543 291 mm (11.5 in.) 424 mm (16.7 in.) 400 mm (15.7 in.) 21 kg (46.2 lbs) Lexmark X544n, X544dn,

X544dtn, X544dw Lexmark X546dtn 422 mm (16.6 in.) 424 mm (16.7 in.) 416 mm (16.4 in.) 25 kg (54.9 lbs) 550-sheet Duo Drawer 133 mm (5.2 in.) 424 mm (16.7 in. 416 mm (16.4 in.) 4 kg (8.7 lb) 650-sheet Duo Drawer 133 mm (5.2 in.) 424 mm (16.7 in. 416 mm (16.4 in.) 4 kg (8.7 lb)

422 mm (16.6 in.) 424 mm (16.7 in.) 416 mm (16.4 in.) 25 kg (54.9 lbs)

Clearances

Description Clearances

X543, X544, X546

1 Rear 101.6 mm (4 in.) 2 Front 508 mm (22 in.) 3 Right side 254 mm (10in.) 4 Left side 76.2 mm (3.0 in.) 5 Top 360 mm (14 in.)*

* Add 133 mm (5.2 in.) to the top if you want to add an optional

650-sheet Duo Drawer (Lexmark X544-6 models only).

- This does not include the 550 sheet tray height.

7525-xxx

General information 1-5

Page 28

7525-xxx

Power and electrical specifications

The following table specified nominal average power requirements for the base printer configurations. All power levels are shown in Watts (W). Maximum current is given in Amperes (A).

Printing states

Average power while printing

Continuous copy 480 W 510 W 510 W 510 W Continuous printing simplex 480 W 540 W 540 W 540 W Continuous printing automatic

duplex*

Average power while idle

Power Saver 22 W 24 W

Stanby 45 W 50 W 50 W 50W Off 0 W

* Automatic duplex is not supported on the X544n.

Lexmark Lexmark 543dn

340 W 370 W n/a 370 W

X544dw,

X544dn, and

X544dtn

23 W (dn only)

Lexmark X544n

23 W 23W

Lexmark X546dtn

Low-voltage models

• 100 to 127 volts (V) (100 – 110 Japan) at 50 to 60 hertz (Hz) nominal

• 90 to 137 volts (90 – 110 Japan), extreme

100 voltage models

• 100 V ac at 47 to 63 hertz (Hz) nominal

• 90 to 110 V ac, extreme

High-voltage models

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

• 198 to 259 V ac, extreme

Notes:

• Using a 220 V ac to 110 V ac power converter with a low voltage printer is not recommended.

• Using an inverter to change DC to AC voltage (12 V to 120 V for example) is not recommended.

• All X54x MFP models will comply with the ENERGY STAR.

• All models ship with Power Saver Mode = On.

• The default timeout to Power Saver = 60 minutes (220V).

• Power Saver can be adjusted to 1-240 minutes.

• Power Saver mode cannot be disabled from the operator panel.

1-6 Service Manual

Page 29

Acoustics

All acoustic measurements are made in accordance with ISO 7779-1999 and reported in conformance with ISO9296:1988-04-15.

Operating mode 1-Meter average sound pressure at 4800 CQ

Lexmark X543

Printing (simplex mono) 46 dBA 46 dBA 47 dBA Printing (simplex color) 47 dBA 47 dBA 48 dBA Printing (automatic

duplex mono) Printing (automatic

duplex color) Copy ADF (Mono) 50 dBA 49 dBA 49 dBA Copy ADF (Color) 50 dBA 50 dBA 50 dBA Scan ADF (Mono) 47 dBA 45 dBA 45 dBA Scan ADF (Color) 46 dBA 45 dBA 45 dBA Idle Inaudible Inaudible Inaudible Quiet Mode (simplex

mono) Quiet Mode (simplex

duplex)

50 dBA 50 dBA 50 dBA

50 dBA 51 dBA 51 dBA

45 dBA 45 dBA 45 dBA

Lexmark X544

Lexmark X546 dtn

7525-xxx

Environment specifications

Environment Specifications

Operating

Air temperature—operating 15.6 to 32.20° C (60 to 90.0° F) Air temperature—power off 10.0 to 43.30° C (50 to 110.0° F) Air relative humidity Relative Humidity 8 to 80% Wet bulb temperature—operating 22.80° C (73.0° F) maximum Web bulb temperature—power off 26.70° C (80.10° F) maximum Altitude 0–3,048 meters (10,000 ft.) Atmospheric pressure 74.6 kPa Ambient operating environment* 15.6 to 32.2° C (60 to 90° F) and 8% to 80% RH

Ship / Storage

Cartridges -40 to 43.3° C (-40 to 110.0° F) Printer with cartridges -40 to 43.3° C (-40 to 110.0° F) Printer without cartridges -40 to 43.3° C (-40 to 110.0° F) Air relative humidity Relative Humidity 8 to 80% Altitude 10,300 meters (34,000 feet) Web bulb temperature—power off 26.70° C (80.10° F) Maximum * In some cases performance specifications (such as paper OCF, EP cartridge usage) are specified to be

measured at an ambient condition.

General information 1-7

Page 30

7525-xxx

Media handling

Input and output sources

Sheet numbers are assuming 20 lb. xerographic paper

Standard input sources

Lexmark X543

Lexmark X544dw, X544dn, X544dtn

Lexmark X544n

Lexmark X546dtn

Standard input tray (250sheet tray)

Manual feed slot (1-sheet) 1 sheet 1 sheet 1 sheet 1 sheet Second tray capacity (650-

sheet Duo Drawer) Multipurpose try capacity

(650-sheet Duo Drawer) Optional 550-sheet drawer N/A N/A 550 sheets 550 sheets

Optional input sources (maximum 1, total of all inputs is 4)

650-sheet Duo Drawer (includes 100-sheet MP feeder)

Multipurpose try capacity (650-sheet Duo Drawer)

Optional third tray capacity (550 sheets)

Maximum total input capacity

Duplex

Type of duplex Integrated

Standard output sources (no optional output sources are available)

250 sheets 250 sheets 250 sheets 250 sheets

550 sheets 550 sheets 550 sheets 550 sheets

100 sheets 100 sheets 100 sheets 100 sheets

550 sheets

(or 100 sheets

in MP feeder)

100 sheets 100 sheets N/A N/A

N/A N/A N/A 550 sheets

901 901 901 1,451

duplex

550 sheets

(or 100 sheets in

MP feeder)

Integrated

duplex

550 sheets

(or 100 sheets in

MP feeder)

n/a Integrated

(tray 3)

duplex

Standard 100-sheet bin 100 100 100 100

a In the 650-sheet Duo Drawer, the 550-sheet tray and the integrated MP feeder count as two independent

input sources. The MF feeder is configured as “cassette” does not show up as Configure MP in the Paper Menu.

1-8 Service Manual

Page 31

Duplex capability

✔—Supported

✔—Supported without size

sensing

✘—Not supported

7525-xxx

Duplex Type

Models

Lexmark X543dn

Lexmark X544n

Lexmark X544dn

Lexmark X544dw

Lexmark X544dtn

Lexmark X546dtn

Media input size specifications

Input source

A4 210 x 297mm

Automatic duplex

✔

(in the

250-sheet tray

Optional 650-sheet

Duo Drawer

Optional 550-sheet

drawer (model

C546dtn only)

650-sheet Duo Drawer)

MP feeder

Manual slot

Duplex

✔✔✔✔✔✔

A5a 148 x 210mm

A6 ✘✘✘

JISb B5a 182 x 257mm

Letter 8.5 x 11 in.

Legal 8.5 x 14 in.

Executivea 7.25 x 10.5 in.

Oficio (Mexico)

Folio 8.5 x 13 in.

Statementa 5.5 x 8.5 in. ✘✘✘

Universalc

148 x 210mm to 216 x 356mm (5.8 x 8.3 in. to

8.5 x 14 in.)

76.x 127mm to 216 x 356mm (3 x 5 in. to 8.5 x 14 in.)

✔✔✔✔✔

✔✔✔✔✔✔

✔✔✔✔✔

✘

✘✘

✔

✔✘

✔✔

✘

✔

✘

General information 1-9

Page 32

7525-xxx

✔—Supported without size

sensing

✘—Not supported

Input source

(in the

250-sheet tray

210mm x 279.4mm to 216mm x 356mm (8.27 in. x 11 in. to

8.5 in. to 14 in.)

7¾ Envelopea 98 x 191mm ✘✘✘

9 Envelopea ✘✘✘

10 Envelopea 105 x 241mm

(4.12 x 9.5 in.)

DL Envelopea 110 x 220mm

(4.3 x 8.7 in.)

C5 Envelopea 162 x 229mm

(6.4 x 9 in.)

B5 Envelopea ✘✘✘✔✔✘

Other envelopea

Length: 98–432mm (3.8–17 in.) Width: 89–297mm (3.5–11.7 in.)

The MP feeder runs slower if A5, Statement, B5, A6, Executive, Statement, Universal (narrower than 210mm), or envelopes are loaded.

Japanese Industry Standard.

Although the user may select Universal paper size for these sources, not all tray guides can be adjusted to all Universal media sizes.

✔✔✔✔✔

✘✘✘

✘✘✘✔✔✘

✘✘✘

Optional 650-sheet

Duo Drawer

Optional 550-sheet

drawer (model

C546dtn only)

650-sheet Duo Drawer)

MP feeder

✔✔

Manual slot

✔

Duplex

✘

1-10 Service Manual

Page 33

Media input type specifications

✔—Supported ✘—Not supported

Input type

Plain paper ✔✔✔✔✔✔

7525-xxx

250-sheet tray

Optional

650-sheet

Duo Drawer

Optional 550-sheet

drawer (model

C546dtn only)

MP feeder

(in 650-sheet

Duo Drawer)

Manual feeder

Duplex

Card stock ✔✔✔✔✔

Transparency ✔✔✔✔✔✘

Recycled

Glossy ✔✔✔✔✔✔

Paper-backed labels ✔✔✔✔✔

Bond ✔✔✔✔✔✔

Envelopes

Rough envelopes ✘✘✘✔✔✘

Letterhead ✔✔✔✔✔✔

Preprinted ✔✔✔✔✔✔

Colored paper ✔✔✔✔✔✔

Light paper ✔✔✔✔✔✔

Heavy paper ✔✔✔✔✔✔

Rough or cotton ✔✔✔✔✔✔

Custom type <x>

For MP feeder and manual feeders, the Default Source Menu displays Manual Paper and Manual Env. Select

Manual Env. for envelopes or when the type in Custom Type <x> is an envelope. For other types, use Manual Paper.

The duplex unit supports this media type as long as the customer has selected the custom type from those types the duplex unit supports.

✔✔✔✔✔✔

✘✘✘✔✔✘

✔✔✔✔✔✔

✘

Media output size and type

There is a single 100-sheet output bin available for this printer and no additional output options.

General information 1-11

Page 34

7525-xxx

Weight ranges for each media type

Material Type Weight Select

2, 5, 7, 8

Paper

Specialty papers Gloss Book 88 to 176 g/m

Card stock—upper limit (grain long)

Card Stock—upper limit (grain short)

Transparency Labels—upper limit Paper 131 g/m Envelopes (Multipurpose

feeder or manual slot only)

For 60 to 176 g/m2 paper, grain long fibers are recommended.

Paper less than 75 g/m2 (20 lb) must be printed with Paper Type set to Light Paper.

100% cotton content maximum weight is 24 lb bond.

28 lb bond envelopes are limited to 25% cotton content.

The duplex unit supports paper weights between 60–105 g/m2 (16–28 pound) grain long bond. The duplex

unit does not support card stock, transparencies, envelopes, and labels.

Lexmark transparency part numbers 12A8240, and 12A8241 are supported from the standard tray, manual slot and the multipurpose feeder.

Paper 90 to 104.9 g/m2 (23.9 to 27.8 lb) must be printed with Paper Type set to Heavy Paper.

Paper 105 to 176 g/m2 (27.9 to 47 lb) must be printed with Paper Type set to Cardstock.

Xerographic or

business paper

Gloss Cover 162 to 176 g/m Index Bristol 120 g/m2 (67 lb)

Tag 120 g/m Cover 135 g/m Index Bristol 163 g/m2 (90 lb)

Tag 163 g/m Cover 176 g/m

Laser printer 170 to 180 g/m2 (45 to 48 lb bond)

Sulfite, wood-free or up to 100% cotton bond

60 to 74. 9 g/m2 grain long (16 to 19.9 lb bond)

75 to 89.9 g/m

2, 5

grain long

(20 to 23.8 lb bond)

90. to 104.9 g/m

grain long

(23.9 to 27.8 lb bond)

105 to 176 g/m (27.9 to 47 lb bond)

60 to 105 g/m

grain long

grain long (60 to 120 lb book)

grain long (60 to 65 lb cover)

(74 lb) (50 lb)

(100 lb) (65 lb)

(35 lb bond)

to 28 lb bond)

Light Paper

Plain Paper

Heavy Paper

Card stock

3, 4

1-12 Service Manual

Page 35

Media guidelines

Paper characteristics

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

• Weight—The printer can automatically feed paper weights from 60 to 176 g/m

long. Paper lighter than 75 g/m performance, use 80 g/m in.), we recommend 90 g/m

• Curl—Curl is the tendency for paper to curl at its edges. Excessive curl can cause paper feeding problems.

Curl can occur after the paper passes through the printer, where it is exposed to high temperatures. Storing paper unwrapped in hot, humid, cold, or dry conditions, even in the trays, can contribute to paper curling prior to printing and can cause feeding problems.

• Smoothness—Paper smoothness directly affects print quality. If paper is too rough, toner cannot fuse to it

properly. If paper is too smooth, it can cause paper feeding or print quality issues. Always use paper between 100 and 300 Sheffield points; however, smoothness between 150 and 200 Sheffield points produces the best print quality.

• Moisture content—The amount of moisture in paper affects both print quality and the ability of the printer

to feed the paper correctly. Leave paper in its original wrapper until it is time to use it. This limits the exposure of paper to moisture changes that can degrade its performance. Condition paper before printing by storing it in its original wrapper in the same environment as the printer for 24 to48 hours before printing. Extend the time several days if the storage or transportation environment is very different from the printer environment. Thick paper may also require a longer conditioning period.

• Grain direction—Grain refers to the alignment of the paper fibers in a sheet of paper. Grain is either grain

long, running the length of the paper, or grain short, running the width of the paper. For 60 to 176 g/m to 47 lb bond) paper, use grain long fibers.

• Fiber content—Most high-quality xerographic paper is made from 100% chemically treated pulped wood.

This content provides the paper with a high degree of stability resulting in fewer paper feeding problems and better print quality. Paper containing fibers such as cotton possesses characteristics that can negatively affect paper handling.

7525-xxx

(20 lb) might not be stiff enough to feed properly, causing jams. For best

(21 lb bond) grain long paper. For paper smaller than 182 x 257 mm (7.2 x 10.1

or heavier paper.

(16 to 47 lb bond) grain

(16

Unacceptable paper

The following paper types are not recommended for use with the printer:

• Preprinted papers with chemicals that may contaminate the printer

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

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

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

• Recycled papers containing more than 25% post-consumer waste that do not meet DIN 19 309, and

weighing more than 80 g/m

• Paper weighing less than 80 g/m

(21 lb)

• Multiple-part forms or documents

General information 1-13

Page 36

7525-xxx

Selecting paper

Using appropriate paper prevents jams and helps ensure trouble-free printing. To help avoid jams and poor print quality:

• Always use new, undamaged paper.

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

on the paper package.

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

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

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

Selecting preprinted forms and letterhead

Use these guidelines when selecting preprinted forms and letterhead:

• Use grain long for 60 to 176 g/m

weight paper.

• Use only forms and letterhead printed using an offset lithographic or engraved printing process.

• Avoid papers with rough or heavily textured surfaces.

Use papers printed with heat-resistant inks designed for use in xerographic copiers. The ink must be able to withstand temperatures up to 200°C (392°F) without melting or releasing hazardous emissions. Use inks that are not affected by the resin in toner. Inks that are oxidation-set or oil-based generally meet these requirements; latex inks might not. When in doubt, contact the paper supplier.

Preprinted papers such as letterhead must be able to withstand temperatures up to 200°C (392°F) without melting or releasing hazardous emissions.

Storing paper

Use these paper storage guidelines to help avoid jams and uneven print quality:

• For best results, store paper where the temperature is 21°C (70°F) and the relative humidity is 40%. Most

label manufacturers recommend printing in a temperature range of 18 to 24°C (65 to 75°F) with relative humidity between 40 and 60%.

• Store paper in cartons when possible, on a pallet or shelf, rather than on the floor.

• Store individual packages on a flat surface.

• Do not store anything on top of individual paper packages.

Using recycled paper and other office papers

As an environmentally conscious company, Lexmark supports the use of recycled office paper produced specifically for use in laser (electrophotographic) printers. In 1998, Lexmark presented to the US government a study demonstrating that recycled paper produced by major mills in the US fed as well as non-recycled paper. However, no blanket statement can be made that all recycled paper will feed well. Lexmark consistently tests its printers with recycled paper (20–100% post-consumer waste) and a variety of test paper from around the world, using chamber tests for different temperature and humidity conditions. Lexmark has found no reason to discourage the use of today's recycled office papers, but generally the following property guidelines apply to recycled paper.

• Low moisture content (4–5%)

• Suitable smoothness (100–200 Sheffield units, or 140–350 Bendtsen units, European)

Note: Some much smoother papers (such as premium 24 lb laser papers, 50–90 Sheffield units) and

much rougher papers (such as premium cotton papers, 200–300 Sheffield units) have been engineered to work very well in laser printers, despite surface texture. Before using these types of paper, consult your paper supplier.

• Suitable sheet-to-sheet coefficient of friction (0.4–0.6)

• Sufficient bending resistance in the direction of feed

1-14 Service Manual

Page 37

7525-xxx

Recycled paper, paper of lower weight (<60 g/m

[16 lb bond]) and/or lower caliper (<3.8 mils [0.1 mm]), and paper that is cut grain-short for portrait (or short-edge) fed printers may have lower bending resistance than is required for reliable paper feeding. Before using these types of paper for laser (electrophotographic) printing, consult your paper supplier. Remember that these are general guidelines only and that paper meeting these guidelines may still cause paper feeding problems in any laser printer (for example, if the paper curls excessively under normal printing conditions).

General information 1-15

Page 38

7525-xxx

Digital imaging specifications

General specifications

ADF Scan speed

Simplex ADF - Up to 5 ppm

Duplex ADF - Up to 5 ppm (page sides)

ADF Document handling

ADF input capacity - 50 sheets.

ADF output capacity - 50 sheets.

ADF document width - 4.9” (125mm) to 8.5”(216mm)

ADF document length - 5” (127mm) to 14.0”(356mm)

Resolution and color depth

Resolution - 1200 dpi optical

•

• CDD 1200 dpi, and 600 dpi. Selectable through electronics

• Color depth - 48 bit RGB output. 16 bit / channel

Flatbed document specifications

Document size- Up to A4 and letter

•

4.5” x 5.5” to 8.5”x11” (SEF)

Flatbed speed

3 seconds to scan, 3 seconds to return.

Scanner operating environments

Temperature - 10C to 35C

•

• Humidity - 15% RH to 85% RH

Storage environments

Temperature - -20C to 43C

•

• Humidity - 5%RH to 95% RH

Tilt

This device should operate within the stated parameters when it is level within 10mm from front to back and 10mm side to side.

1-16 Service Manual

Page 39

Scan and copy specific specifications

Scan Resolutions

Optical - 600 dpi (Local Twain only)

•

• Enhanced (vial Lexmark Scan Center) - 1200 X 1200 dpi, 2400 X 2400 dpi, 4800 X 4800 dpi, 9600 X 9600

dpi, 19200 X 19200 dpi

Output resolutions

•

Mono - 600 X 600 dpi

• Color - 300 X 300 dpi

Duplex scan

Duplex and copy is available only on X544, and X546 series machines.

Scan file output formats

TIFF

•

• JPEG

• PDF

7525-xxx

Supported compressions

•

PDF - (1 bit,- JBIG2 CCIT G4, Flate), (8/24 bit - Flate JPEG)

• TIFF - (1 bit - CCITT G4), (8/24 bit - Packbits, LZW)

• JPG - (8/24 bit-JPG)

Supported scan destinations

•

Temporary profile from a user’s PC

• Scan to PC via network TWAIN

• Scan to PC using Web applet

• Scan to E-Mail

• Scan to USB (X544 models only)

• Lexmark Scan Center

Multiple copies

999 copies maximum

Reduce / Enlarge

-25% to 400%

General information 1-17

Page 40

7525-xxx

Fax specifications

Phone network connectivity

Phone networks types supported PSTN or analog PABX (RJ-11) ITU COMPATIBILITY

Standard Resolution Fine Superfine Ultrafine Coding

Modem speed V.34 2,400-33,600 BPS,

Compression Error correction ITU T.30

Line interface selection

Modular Plug Out Band Signal Level

Input Level Range Ring Detection

Group 3/ECM 8 x 3.85 pels/mm (200X100dpi) (204x98) 8 x 7.7 pels/mm (200X200dpi) (204x196)

11.8 x 11.8 pels/mm(300x300 dpi) (204x391)

15.7 x 15.7 pels/mm (400x400 dpi) (408x391) ITU T.4 and T.6(MH, MR, MMR, JPEG)

V.17 7,200-14,400 BPS, V.27 2,400-4,800 BPS, V.29 7,200-9,600 BPS

MH, MR, MMR, JPEG

Dual RJ-11C Guaranteed North American and Europe PTT standard

-16dBm ~ -59dBm Complies with all regulatory requirements

Fax resolutions

Receive 200x100 dpi, 200x200 dpi, 300x300 dpi,

Send 200x100dpi, 200x200 dpi, 300x300 dpi

400x400 dpi, 204x98 dpi, 204x196 dpi, 204x391 dpi, 408x391 dpi

Miscellaneous FAX specifications

Fax memory 4 MB Flash (More than 320 pages based on ITU chart #1)

Speed dial Yes. 99 entries Transmission Approximately 3 seconds per page Color fax Yes Fax from PC Yes. Suppor ted using PostScript driver for both local and

Caller ID Yes Junk FAX blocking Yes - based on caller ID and remote station ID Tone/Pulse Tone: Default, Pulse: Yes Fax forward Yes Broadcasting Yes. 12 destinations External phone interface Yes Manual mode Yes Fax shortcuts Yes. Fax content Text, text/photo, photo Fax preservation Yes Halftoning Yes

User selectable parameters are stored in NVRAM.

network attach modes.

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Tools required for service

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

7.0 mm nut driver Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Flash light (optional)

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General information 1-19

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Acronyms.

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

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HVU High voltage unit Hz Hertz INTL International ITC Internal Tray Card ITU Image Transfer Unit KBlack (Key) LAN Local area network LASER Light amplification by stimulated emission of radiation LCD Liquid crystal display LCM Liquid Crystal Module LD Laser Diode LED Light emitting diode LEF Long edge feed LES Lexmark Embedded Solution (applications) LSU Laser Scanning Unit LV Low Voltage LVPS Low voltage power supply M Magenta MB Megabyte MDC Motor Driver Control MFD Multifunction Device MFP Multifunction Printer MH Message handling MIF Motor interface mm Millimeter MMR Modified modified read MPF Multipurpose feeder MR Modem ready MROM Masked Read Only Memory MS Microswitch NAND NAND (usage: NAND gate) NVM Nonvolatile Memory NVRAM Nonvolatile Random Access Memory OCF Operator correctable failure OCR Oil coating roll OEM Original Equipment Manufacturer OHP Overhead projector OPC Optical photo conductor OPT Optical Sensor PC Photoconductor PDF Portable Document Format PICS Problem isolation charts PIN Personal identification number PIXEL Picture element PJL Printer Job Language POR Power-on reset POST Power-on self test PPDS Personal Printer Data Stream ppm Pages per minute PQET Print Quality Enhancement Technology PRC Peoples' Republic of China PSC Parallel Synchronous Communications PSD Position Sensing Device PSO Participating Standards Organization

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General information 1-21

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PWM Pulse Width Modulation RAM Random access memory RFID Radio frequency identification RH Relative humidity RIP Raster image processor ROM Read-only memory ROS Read-only storage RPM Revolutions Per Minute SCC Scanner Control Card SDRAM Synchronous Dynamic Random Access Memory SEF Short edge feed SIMM Single Inline Memory Module SOL Solenoid SOS Start of scan SRAM Static random access memory TAR Toner Add Roll TPS Toner Patch Sensing TTM Tandem Tray Module TVOC Total Volatile Organic Compound UAT Universally Adjustable Tray UPR Used Parts Return USB Universal Serial Bus VVolts V ac Volts alternating current V dc Volts direct current VOIP Voice over internet protocol VOM Volt Ohmmeter VTB Vacuum Transport Belt XPS XML Paper Specification YYellow

1-22 Service Manual

Page 45

2. Diagnostic information

CAUTION

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

Start

Begin here to locate the service error code, user status message, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer. They will lead you to solutions or service checks, including use of various tests.

• Does the POR stop? Check the “POR (Power-On Reset) sequence” on page 2-2

• Do you have a symptom, rather than an error message? Locate your symptom, and take the appropriate

action:

– “Printer symptom table” on page 2-3 – “Scan / fax / copy symptom table” on page 2-4

• If you have an error message or user message, check the following: – “Service error messages” on page 2-15 – “User status and attendance messages” on page 2-6 – “Paper Jam messages” on page 2-13 – “Service checks” on page 2-31 for individual error messages

• Additional information can be found at the following locations: – “Operator panel and menus” on page 2-2 – “POR (Power-On Reset) sequence” on page 2-2 – “Print engine theory” on page 3-57

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Diagnostic information 2-1

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7525-xxx

POR (Power-On Reset) sequence

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

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

1. The LED turns on.

2. The main fan turns on.

3. The operator panel turns on.

4. A partial row of pixels appears.

5. The operator panel display clears.

6. Another row of pixels appears.

7. The operator panel display clears again.

8. The operator panel displays system information. For example:

*256MB 500Mhz

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

10. The operator panel LED starts blinking.

The following errors or messages may appear:

• Close Door or Insert Cartridge display if the upper front cover is open or the print cartridge is missing.

• Any cartridge errors, such as Defective Cartridge or Missing Cartridge.

11. Ready appears on the display.

12. The main drive motor turns on.

13. The EP drive assembly drives the developer shaft located in the toner cartridge.

14. The exit rollers turn.

15. The printer calibrates.

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Symptom tables

Printer symptom table

Symptom Action

Dead printer Go to “Dead printer service check” on page 2-35. Operator panel—one or more buttons do

not work. Operator panel—display is blank. Printer

sounds five beeps. Operator panel—display is blank. Go to “Operator panel display blank, five beeps” on

Operator panel continuously displays all diamonds and does not complete POST.

Pages print blank after replacing the controller board.

Tray linking does not work. • Check that the same size and type of paper are in each tray.

Unexpected page breaks occur • Increase the Print Timeout value on the operator panel

Multipurpose feeder has constant misfeeds or jams.

Page that jammed does not reprint after you clear the jam.

Printing speed reduced for more than 10 pages. May happen after a service call.

Pages print blank after replacing the controller board.

7525-xxx

Go to “One or more operator panel buttons fail” on

page 2-42.

Go to “Operator panel display blank, five beeps” on

page 2-42.

Go to “Operator panel display blank, five beeps” on

page 2-42.

When replacing the controller board, verify the cable from the high-voltage power supply is seated properly. The cable may have come loose from the HVPS.

Warning: A blank page that should have toner on it could be an indication that toner is applied to the ITU belt but not transferred. Therefore the toner goes into the ITU cleaner which cannot process massive amounts of toner. It is important to prevent extensive blank pages from being processed if they should have toner on them.

• Check the location of the paper guides.

• The multipurpose feeder does not automatically sense the paper size. You must set the size from the Paper Size/Type menu.

• Print a menu settings page, compare the settings for each tray, and adjust on the operator panel, if necessary.

(Settings–>General Settings–>Timeouts–>Print Timeout).

• Remove and flex the paper in the tray. Reload the paper, and try printing.

• Turn the paper over inside the tray.

• Make sure the feeder is properly installed.

• Make sure the paper is loaded correctly in the tray.

• Make sure the paper is not damaged.

• Make sure the paper meets specifications. See “Media

input type specifications” on page 1-11.

• Make sure the paper guides are positioned correctly for the paper size loaded in the tray.

Jam Recovery may be set to Off. Change the setting to Auto or On on the operator panel (Settings–>General settings–>Print Recovery–>Jam Recovery.)

Check the narrow media sensor cable is correctly connected at the sensor, and the cable is correctly connected to JBIN1 on the controller board.

When replacing the controller board, verify the cable from the high-voltage power supply is seated properly. The cable may have come loose from the HVPS.

Diagnostic information 2-3

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Symptom Action

Unexpected page breaks occur • Increase the Print Timeout value on the operator panel

Scan / fax / copy symptom table

Symptom Action

840.xx scanner error Go to “840.xx service check” on page 2-63. ADF won’t duplex (Duplex ADF only) Go to “ADF Duplex service check” on page 2-70. ADF skew Go to “ADF feed errors service check” on page 2-69. Multiple pages feed into ADF Documents wont feed into ADF Scanner makes buzzing noise on startup or

during a scan. Document feeds, but jams in ADF. Go to “ADF paper jam service check” on page 2-68. Black streaks on scans Go to “ADF streak service check” on page 2-67. Blank page Go to “Black or blank page copy service check” on Black page No dial tone Go to “Modem / fax card service check” on page 2-71. Machine dials a number but fails to make a

connection with another fax machine. Incoming fax has blank spaces or poor

quality.

Invalid fax partition, or fax partition too small.

Some words on an incoming fax are stretched.

Faxes fail to transmit. Go to “Fax transmission service check” on page 2-72. Fax reception fails. Go to “Fax reception service check” on page 2-74. Rattling noise coming from the ADF unit Inspect the ADF separator roll and ADF separator pad for proper

(Settings–>General Settings–>Timeouts–>Print Timeout.)

Go to “Flatbed home position service check” on page 2-66.

page 2-65.

The other fax machine may be turned off. Ask the fax recipient to check their machine.

1. The sending fax machine may be faulty.

2. The sending fax machine may have a dirty document glass.

3. A noisy phone line can cause errors.

4. Check the MFP print quality by making a copy.

5. The print cartridge may be empty. Replace as necessary. See “Format Fax Storage” on page 3-34.

The sending fax machine had a temporary jam.

installation. If needed, remove the separator pad and separator roll and reinstall them. See “ADF separator pad” on page 4-87 and “ADF separator roll assembly” on page 4-88. for removal instructions.

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Print quality symptom table

Symptom Action

Background Go to “Print quality—background” on page 2-49. Blank page Go to “Print quality—blank page” on page 2-50. Blurred or fuzzy print Go to “Print quality—blurred or fuzzy print” on page 2-52. Half-color page Go to “Print quality—half-color page” on page 2-52. Horizontal banding Go to “Print quality—horizontal banding” on page 2-52. Horizontal line Go to “Print quality—horizontal line” on page 2-53. Insufficient fusing Go to “Print quality—insufficient fusing” on page 2-53. Missing image at edge Go to “Print quality—missing image at edge” on page 2-53. Mottle (2–5mm speckles) Go to “Print quality—mottle (2–5mm speckles)” on

Narrow vertical line Go to “Print quality—narrow vertical line” on page 2-54. Random marks Go to “Print quality—random marks” on page 2-54. Residual image Go to “Print quality—residual image” on page 2-55. Solid color page Go to “Print quality—solid color page” on page 2-56. Vertical banding Go to “Print quality—vertical banding” on page 2-56. Color problems Go to “Color theory” on page 3-71. Light print on solids Go to “Media guidelines” on page 1-13.

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page 2-53.

Diagnostic information 2-5

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Error codes and messages

User status and attendance messages

User primary message Explanation

Busy Wait for the message to clear. Calibrating The printer is performing a color adjustment. Close Door Message clears when upper and lower doors are closed. Check Config ID The printer configuration ID is invalid. Check Model Name Message clears when a valid model name is set. Check Serial Num Message clears when a valid serial number is set. <color> Low Replace the toner cartridge, and then wait for the message to clear. Defragmenting Flash

DO NOT POWER OFF

Flushing buffer Wait for the message to clear. Formatting Flash

DO NOT POWER OFF

Hex Trace This message appears between status messages and warnings. Wait for the

Imaging Kit Replace the imaging kit, and then press Select ( ) to clear the message and

Insert Tray <x> This message is displayed when the printer requests the user to insert tray x before it

No Analog Phone Line

Memory Full, cannot send faxes

Insert Duplex Page in Tray <x>

Install Tray <x> or Cancel job

Load <source> <custom string>

The printer is performing the defragmentation operation of flash memory. Wait for the message to clear.

Warning: Do not turn the printer off while this message appears on the display.

Wait for the message to appear. Warning: Do not turn the printer off while this message appears on the display.

message to clear.

continue printing.

can continue printing the job. The printer needs to pick media from the missing tray or the trays below it.

Tray x=Tray 1, Tray 2, Tray 3 Note: This message displays when refilling the trays during a job. Before filling tray a

tray, take the printer offline by pressing Stop , and wait for pages to stop feeding into the output bin.

The following actions can be taken:

• Insert the requested tray.

• Cancel the current job

An analog line is not detected as being plugged into the modem. If the device is in Analog mode, this has a source of Fax. If the device is in Fax Server mode, and the 'Enable analog receive' Fax Server setting is set to 'On', this has a source of Fax Receive. If the device is in Fax Server mode and the 'Enable analog receive' Fax Server setting is set to 'Off', then this IR is not generated.

After a start, there is no memory to do the fax job. Attempted fax is cancelled.

Reload printed page in tray <x>. Cancel Job appears if the job can be cancelled.

Printer detects that tray <x> is missing, where x is 1 or 2. This message appears if the job was begun, but the paper has not yet been retrieved. The tray is no longer detected. Replace the indicated tray.

Printer does not detect media meeting the description <custom string> in <source>, where <source> is Tray 1, Tray 2, Tray 3, Multi-Page Feeder (MP feeder), or Envelope Feeder.

• Load the input source with the correct type and size media.

• Cancel the current job.

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User status and attendance messages (continued)

User primary message Explanation

Load <source> <custom type>

Load <source> <size>

Load <source> <type> <size>

Load single sheet <custom type>

Load single sheet <custom string>

Load single sheet <size>

Load single sheet <type> <size>

PJL ST Message Try one or more of the following:

Power Saver The printer is saving power while it waits for the next print job.

Programming Code The printer is receiving a file that is a code update. Wait for the message to clear.

Programming Flash Fonts and macros are being written to flash. Wait for the message to clear. Ready The printer is ready to print.

Printer does not detect media meeting the description <custom type> in <source>, where <source> is Tray 1 or Tray 2, Tray 3.

• Load the input source with the correct type and size media.

• Cancel the current job.

Printer does not detect media meeting the size requested in the source indicated.

• Load the input source with the correct type and size media.

• Cancel the current job.

Printer does not detect media meeting the size or type requested in the source indicated.

• Load the input source with the correct type and size media.

• Cancel the current job.

Printer does not detect media meeting the description <custom type> in the single sheet feeder (manual feeder).

The following actions can be taken:

• Load paper, and the job continues.

•press Select ( ), and choose an alternate source for media.

• Cancel the current job.

Printer does not detect media meeting the description <custom string> in the single sheet feeder (manual feeder).

The following actions can be taken:

• Load paper and the job continues.

•press Select ( ), and choose an alternate source for media.

• Cancel the current job.

Printer does not detect media meeting the description <size> in the single sheet feeder (manual feeder).

The following actions can be taken:

• Load paper and the job continues.

•press Select ( ), and choose an alternate source for media.

• Cancel the current job.

Printer does not detect media meeting the description <type> and <size> in the single sheet feeder (manual feeder).

The following actions can be taken:

• Load paper and the job continues.

•press Select ( ), and choose an alternate source for media.

• Cancel the current job.

•press Select (

ait for the message to clear.

• W

• Send a job to print.

•Press Select ( ) to warm the printer to normal operating temperature.

Afterwards, Ready appears.

Warning—Potential Damage: Do not turn the printer off while this message appears on the display.

) to clear the message, and continue printing.

Diagnostic information 2-7

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7525-xxx

User status and attendance messages (continued)

User primary message Explanation

Remove Paper ADF

Remove Paper Standard Bin

Remove Packaging Material

Unplug and Change Mode

Replace Black Imaging Unit

Replace Color Imaging Unit

Replace <color> Cartridge

Std Bin Full The following actions can be taken:

Tray <x> Empty The following actions can be taken:

Tray <x> Low Load the paper tray or other source with the correct paper type and size. Tray <x> Missing Insert the specified tray into the printer. Unplug and Change

Mode Unsupported Mode Camera is not in a proper mode to use the Pict Bridge feature. Unplug the camera

Unsupported USB Device, Please Remove

Unsupported USB Hub, please remove

Waiting The printer has received data to print, but is waiting for an End-of-job command, a

Waiting, too many events

Waste Toner Box The waste toner bottle is nearly full. Press Select ( ) to clear the message and

30.xx <color> Toner Cart Missing

This posts when there is paper detected in the ADF upon POR or when the cover is closed (or any other situation that re-inits the scanner). Message clears when paper is removed.

The standard output bin is full or nearly full. Remove the media from the bin.

Packaging material is detected by the printer. Remove the packaging material and press Continue.

Camera is not in a proper mode to use the PictBridge feature. Unplug the camera cable to the printer, and change the camera mode.

Replace the Black Imaging Unit.

Replace the Color Imaging Unit.

Replace the toner cartridge of the indicated color. The printer continues after the toner door is closed.

• Remove paper from the standard exit bin to clear the message and continue printing.

•Press Select ( ) to clear the message and continue printing.

• Load the paper tray or other source with the correct paper type and size.

•Press Stop ( ) and then press Select ( ) to cancel the current job.

Camera is not in a proper mode to use the PictBridge feature. Unplug the camera cable to the printer, and change the camera mode.

cable to the printer and change the camera mode. Remove the unrecognized device from the USB port on the front of the printer.

Remove the unrecognized USB hub/device from the USB port on the front of the printer.

Form Feed command, or additional data. The following actions can be taken:

•Press Select ( ) to print the contents of the buffer.

• Cancel the current print job.

Wait for the message to clear. Warning—Potential Damage: Do not turn the printer off while this message appears

on the display.

continue printing. The specified toner cartridge is missing. Re-install the missing toner cartridge to clear

the message, and then continue printing. If the message recurs remove and re-install the cartridge. Listen for the click to ensure the cartridge is installed properly. Close the front cover.

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Page 53

User status and attendance messages (continued)

User primary message Explanation

31.xx Defective <color> cartridge

31.xx Defective Imaging Kit.

32.xx Replace unsupported <color> Cartridge

34 Short Paper • press Select (

35 RES Save Off Deficient Memory

37 Insufficient Collation Area

The specified cartridge is defective. Try one of the following:

• Open and close the top cover.

• Remove and re-install the cartridge(s). Listen for the click to ensure the cartridge is installed properly.

• Turn the printer power off and turn the printer power on.

If the message persists, replace the cartridge with a new one, and close the front cover.

Defective imaging kit. Try one or more of the following:

• Open and close the top cover.

• Remove and re-install the cartridge(s). Listen for the click to ensure the cartridge is installed properly.

• Turn the printer power off, and then turn the printer power on.

If the message persists, determine if the imaging kit counter is greater than 15,000 cycles. It it is, then replace the entire kit. See “Imaging unit (IU) removal” on

page 4-40. If the counter is below 250,000 cycles, replace only the photoconductors.

Remove the specified cartridge, replace with a supported cartridge, and close the front cover.

) to clear the message and continue printing.

The printer does not automatically reprint the page that prompted the message.

• Check tray length and width guides to ensure paper is properly fitted in the tray.

• Make sure the print job is requesting the correct size of paper.

• Adjust the Paper Size setting for the size paper you are using. If MP Feeder Size is set to Universal, make sure the paper is large enough for the

formatted data.

• Cancel the current job.

This message displays when the printer lacks sufficient memory to enable Resource Save. This message usually indicates the user has allocated too much memory for one or more of the printer link buffers; however, modification of other printer settings which affect the amount of available memory may also create this condition. If restoration of Resource Save is required after this message is received, the customer should install additional memory or set each link buffer to Auto. Once all link buffers are returned to Auto, you should exit the menu to activate the link buffer changes. Once the printer returns to the Ready state, you can enable Resource Save and go back and modify the link buffers again. Note the reduction of available memory to the link buffers when Resource Save has been enabled, and compare it to the memory available when Resource Save is disabled.

•press

• Install additional memory.

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

The following actions can be taken:

•press Select ( ) to print the portion of the job already stored, and begin collating

•press Menus ( ) to access the Busy/Waiting Menu.

Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu.

Select ( ) to disable Resource Save and continue printing.

To enable Resource Save after you get this message:

- Make sure the link buffers are set to Auto, then exit the menus to activate the link buffer changes.

- When Ready is displayed, enable Resource Save.

the rest of the job.

The following functions are available.

- Cancel Job

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Diagnostic information 2-9

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User status and attendance messages (continued)

User primary message Explanation

37 Insufficient memory for flash defragment operation

38 Memory Full This message is displayed when the printer is processing an incoming job and there

39 Complex Page This message is displayed when a page is too complex to print.

40 <color> Invalid Refill, change cartridge

50 PPDS Font Error This error only occurs when a printer is formatting PPDS print data.

51 Defective Flash Detected

This message is displayed when insufficient printer memory is available to perform Flash Memory Defragment operation.

This message appears prior to the actual start of the defragment operation.

Select ( ) to stop the defragment operation.

press To perform the defragment operation, you can:

• Delete fonts, macros, and other data in RAM.

• Install additional printer memory.

•press Menus ( ) to access the Busy/Waiting Menu.

The following functions are available using the Busy/Waiting Menu:

- Cancel Job

- Reset Printer

Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu.

is not enough memory available to continue processing the job. The following actions can be taken:

• Determine how to make more memory available to your print job by:

- Deleting fonts, macros and other data in RAM.

- Simplify your print job.

- Install additional memory

•press Select ( ) to clear the message and continue printing.

The job may not print correctly.

•press Menus ( ) to access the Busy/Waiting Menu.

The following functions may be available:

- Cancel Job

The following actions can be taken:

•press

• Simplify the print job.

•press Menus ( ) to access the Busy/Waiting Menu.

Note: Menu Lockout does NOT prevent access to the Busy/Waiting Menu. Replace the toner cartridge with a new one.

The PPDS interpreter has detected a font error. When a specific font, which is not installed, is requested based on a PPDS mode Set Font Global command, a Select Code Page command, or a Comprehensive Font Selection command, and the printer Best Fit setting is off. If Best Fit is on, the printer performs a best fit search to find a similar font, and this error does not occur.

This error also displays when the printer receives invalid PPDS download font data. The following actions can be taken while this message is displayed:

•press Select ( to clear the message and continue printing.

•press Menus ( to access the Busy/Waiting Menu.

press You must install different flash memory before you can download any resources to

flash.

Select ( to clear the message and continue printing.

The job may not print correctly.

The following functions may be available:

- Cancel Job

- Reset Printer

The job may not print correctly.

The following functions may be available:

- Cancel Job

Select ( to clear the message and continue printing.

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Page 55

User status and attendance messages (continued)

User primary message Explanation

52 Flash Full • press

• Delete fonts, macros, and other data stored on the flash memory.

• Install a larger capacity flash memory card.

53 Unformatted Flash press

You must format the flash memory before you can store any resources on it. If the error message remains, the flash memory may be defective and require replacing.

54 Standard Network Software Error

54 Network <x> Software Error

56 Standard USB Port Disabled

58 Too many Flash Options Installed

58 Too Many Trays Installed

59 Incompatible Tray <x>

82 Waste Toner Nearly Full

82 Waste Toner Missing

This message is displayed when the RIP software detects that a network port is installed but cannot establish communications with it.

•press

• Program new firmware for the network interface.

• Turn the printer power off and then back on to reset the printer.

The printer disables all communications to the associated network interface. No data may be received or sent from or to the associated interface. The user can program new firmware in the network using the parallel port after this message clears.

•press Select ( to clear the message and continue printing.

• Program new firmware for the network interface.

• Turn the printer power off and then back on to reset the printer.

This message may appear when data is sent to the printer across a USB port, but the port is disabled.

Note: Once the error is displayed the first time, reporting of further errors is suppressed until the printer is reset or menus are entered.

The following actions can be taken:

•press

•press Menus ( to access the Busy/Waiting Menu.

Make sure the USB Buffer menu item is not set to Disabled. (press Menus to access the Administrative Menus, select Network/Ports, USB Menu, and USB Buffer.)

1. Turn off and unplug the printer.

2. Remove the excess flash memory.

3. Plug in the printer, and turn it on.

1. Turn off and unplug the printer.

2. Remove the additional trays.

3. Plug in the printer, and turn it on.

1. Turn off and unplug the printer.

2. Remove the specified incompatible tray.

3. Plug in the printer, and turn it on.

Try one or more of the following:

• Replace the waste toner bottle, and then press Select ( ) to clear the message

•press Select ( ) to clear the message and continue printing.

Order the waste toner bottle so it will be available when the replacement message is displayed. Once the replacement message is displayed, the printer will not continue until the waste toner is replaced.

Waste toner box must be present. Install the waste toner bottle.

• Replace the specified toner cartridge.

Select ( to clear the message and continue printing.

The job may not print correctly.

Select ( to clear the message.

Any data received on the USB port is discarded.

The following functions may be available:

- Turn the printer power off and then back on to reset the printer.

- Reset Active Bin

- Check Supply Levels

and continue printing. See Go to “Waste toner bottle” on page 4-67.

7525-xxx

Diagnostic information 2-11

Page 56

7525-xxx

User status and attendance messages (continued)

User primary message Explanation

82.xx Waste toner nearly full

88 <color> Toner Low The term <color> includes black, cyan, magenta, and yellow.

88 <color> Cartridge Early Warning

88 Replace <color> Cartridge

Scanner ADF cover open

Scan job too long The scan job exceeds the maximum number of pages

Paper cleared Paper is cleared from ADF

The following actions can be taken:

• Replace the waste toner bottle, and then press Select ( ) to clear the message and continue printing. See Go to “Waste toner bottle” on page 4-67.

•Press Select ( ) to clear the message and continue printing.

• Order the waste toner bottle so it will be available when the replacement message is displayed. Once the replacement message is displayed, the printer will not continue until the waste toner is replaced.

• Replace the specified toner cartridge.

•press

The term <color> includes black, cyan, magenta, and yellow.

• Replace the toner cartridge and press

The term <color> includes black, cyan, magenta, and yellow.

• Replace the toner cartridge and press

The cover to the ADF is open.

• Close the ADF cover. If this doesn’t remedy the problem, Go to “ADF cover open

• Break the scan job into multiple small jobs.

• Cancel the scan job.

• Cancel job

• Restart job - This can only be performed if job recovery is enabled and the job can

Select ( to clear the message and continue printing.

Select ( to clear the message and

continue printing.

Select ( to clear the message and

continue printing.

service check” on page 2-67”.

be restarted. A new job with the same parameters is started.

2-12 Service Manual

Page 57

Paper Jam messages

Paper jam messages (2xx)

Error code Description Action

2xx paper jams

7525-xxx

200.xx Paper Jam Check <area>

200.xx Paper Jam <x> Pages Jammed

201.xx Paper Jam Check <area>

201.xx Paper Jam <x> Pages Jammed

202.xx Paper Jam Check <area>

202.xx Paper Jam <x> Pages Jammed

230.xx Paper Jam Check <area>

230.xx Paper Jam <x> Pages Jammed

A single page of media jam at the input sensor.

Multiple pages of media are jammed at the input sensor.

A single page of media is jammed between the input and exit sensors.

Multiple pages of media are jammed between the input and exit sensors.

A single page of media is jammed at the exit sensors.

Multiple pages of media are jammed at the exit sensor

A single page of media is jammed at the inner door.

Multiple pages of media are jammed at the inner door.

Remove the tray1 unit, open the front door, and remove the print cartridge to access the jam area. Remove the jammed page. See “200 paper jams” on page 3-41.

Open the front door and remove the print cartridge to access the jam area. Remove all the jammed pages. See “200 paper

jams” on page 3-41.

Open the front door and remove the print cartridge to access the jam area. Remove the jammed page. See “201 paper jam”

on page 3-41.

Open the front door and remove the print cartridge to access the jam area. Remove all the jammed pages. See “201 paper

jam” on page 3-41.

Open the printer rear door to access the jam area. Remove the jammed page. See

“202 paper jam” on page 3-42.

Open the printer rear door to access the jam area. Remove all the jammed pages. See “202 paper jam” on page 3-42.

Remove the jammed page. See “230

paper jam” on page 3-43.

Remove all the jammed pages. See “230

paper jam” on page 3-43.

5 Paper

Check Duplex

241.xx Paper Jam Check <area>

241.xx Paper Jam <x> Pages Jammed

242.xx Paper Jam Check <area>

242.xx Paper Jam <x> Pages Jammed

243.xx Paper Jam Check <area>

243.xx Paper Jam <x> Pages Jammed

Jam

Paper jam in the duplex area. Remove all pages. See Go to “235 paper

Paper jam in the primary tray. • Open the door, and remove all the

A single or multiple page media jam in the 650-sheet Duo Drawer (tray 2).

Multiple pages of media are jammed in the 650-sheet Duo Drawer (tray 2).

A single or multiple page media jam in the optional 550-sheet drawer (tray 3).

Multiple pages of media are jammed in the optional 550-sheet drawer (tray 3).

jam” on page 3-43.

jammed pages. See “24x paper jam”

on page 3-43.

• Verify the proper tray settings for the media.

• Fan the media.

Check the condition of the pick tires.

See “24x paper jam” on page 3-43.

Open the door, and remove all the jammed pages. See “24x paper jam” on

page 3-43.

Diagnostic information 2-13

Page 58

7525-xxx

Paper jam messages (2xx) (continued)

Error code Description Action

250.xx Paper Jam Check Manual Feeder

250.xx Paper Jam <x> Pages Jammed

271.22 Paper Jam Check <area>

271.22 Paper Jam <x> Pages Jammed

290.02 Scanner ADF Feed Jam

290.10 Scanner Static Jam

290.20 Scanner Static Jam-Paper Present

290.30-Scanner Static Jam-Paper Stop

A single page of media is jammed in the multipurpose feeder.

Multiple pages of media are jammed in the multipurpose feeder.

Output bin 1 declared jam.

The scanner ADF has failed to feed a page to the ADF interval sensor.

Scanner ADF detects paper at the first scanner sensor while the ADF is in an idle state.

This message occurs when paper is detected in the ADF during a POR, or when the MFP is starting up.

This message displays when paper is inserted past the paper stop on the ADF.

Open tray 2 to access the jam area. Remove the jammed page. See “250

paper jam” on page 3-43.

Open tray 2 to access the jam area. Remove all the jammed pages. See “250

paper jam” on page 3-43.

Remove the sheet of paper rom the ADF. Retry the job. If the error recurs, Go to

“ADF paper jam service check” on page 2-68.

Remove all paper from the ADF. Retry the job. If the error recurs, Go to “ADF paper

jam service check” on page 2-68.

Remove original documents from the ADF.

291.00 Scanner Jam, remove all originals from the scanner

291.01 Scanner Jam, remove all originals from the scanner

292 Scanner jam, remove all originals from the scanner

293 Replace all originals if restarting job

2 Flatbed cover

3.0

open

294.04 Scanner jam, remove all originals from the scanner

294.05 Scanner jam, remove all originals from the scanner

Scanner ADF detects paper at the second scanner sensor while the ADF is in an idle state.

This message is posted if a jam is detected at the first scanner sensor.

This message appears if the ADF cover is open while paper is fed through the ADF.

No paper sensed in the ADF. Ensure that the paper present actuator is

The MFP senses that the flatbed cover is open.

Jam at the ADF exit sensor. Remove all paper from the ADF. If the error

A jam is detected at the ADF exit sensor.

Remove the paper from the ADF, and close the ADF cover. If the error recurs, Go to

“ADF cover open service check” on page 2-67.

in the correct position. See “ADF paper

jam service check” on page 2-68.

Close the flatbed cover. See “ADF cover

open service check” on page 2-67.

recurs, “ADF paper jam service check”

on page 2-68.

2-14 Service Manual

Page 59

Service error messages

Service error messages (1XX, 8XX and 9xx)

Error code Description Action

7525-xxx

106.xx Service Yellow Printhead

106.01 Service Yellow Printhead

106.02 Service Yellow Printhead

106.03 Service Yellow Printhead

106.04 Service Yellow Printhead

106.05 Service Yellow Printhead

106.08 Service Yellow Printhead

106.11Service Yellow Printhead

Yellow printhead error. Perform a POR. If the problem persists, go

The yellow printhead lost HSYNC. Perform a POR. If the problem persists, go

The yellow printhead failed to complete servo.

The yellow printhead mirror motors failed to achieve lock.

The yellow printhead mirror motors lost PLL motor lock.

Failure reading NVRAM from printhead.

The yellow laser showed bad in EMS testing.

Failure writing data to printhead Perform a POR. If the problem persists, go

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

106.12 Service Yellow Printhead

106.13 Service Yellow Printhead

107.xx Cyan Printhead Error

107.01 Service Cyan Printhead

107.02 Service Cyan Printhead

107.03 Service Cyan Printhead

107.04 Service Cyan Printhead

107.05 Service Cyan Printhead

Failure reading data from the printhead Perform a POR. If the problem persists, go

Printhead declared error Perform a POR. If the problem persists, go

Cyan printhead error. Perform a POR. If the problem persists, go

The cyan printhead lost HSYNC. Perform a POR. If the problem persists, go

The cyan printhead failed to complete se

The cyan printhead mirror motors failed to achieve lock.

The cyan printhead mirror motors lost PLL motor lock.

Failure reading NVRAM from the cyan printhead.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Diagnostic information 2-15

Page 60

7525-xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

107.08 Service Cyan Printhead

107.11Service Cyan Printhead

107.12 Service Cyan Printhead

107.13 Service Cyan Printhead

108.xx Service Magenta Printhead

108.01 Service Magenta Printhead

108.02 Service Magenta Printhead

108.03 Service Magenta Printhead

The cyan laser showed bad in EMS testing.

Failure writing data to printhead Perform a POR. If the problem persists, go

Failure reading data from the printhead Perform a POR. If the problem persists, go

Printhead declared error Perform a POR. If the problem persists, go

Magenta printhead error. Perform a POR. If the problem persists, go

The magenta printhead lost HSYNC. Perform a POR. If the problem persists, go

The magenta printhead failed to complete servo.

The magenta printhead mirror motors failed to achieve lock.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

108.04 Service Magenta Printhead

108.05 Service Magenta Printhead

108.08 Service Magenta Printhead

108.11Service Magenta Printhead

108.12 Service M

agent

a Printhead

108.13 Service Magenta Printhead

109.xx Service Black Printhead

109.01 Service Black Printhead

The magenta printhead mirror motors lost PLL motor lock.

Failure reading NVRAM from the magenta printhead.

The magenta laser showed bad in EMS testing.

Failure writing data to printhead Perform a POR. If the problem persists, go

Failure reading data from the printhead Perform a POR. If the problem persists, go

Printhead declared error Perform a POR. If the problem persists, go

Black printhead error. Perform a POR. If the problem persists, go

The black printhead lost HSYNC. Perform a POR. If the problem persists, go

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

2-16 Service Manual

Page 61

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

7525-xxx

109.02 Service Black Printhead

109.03 Service Black Printhead

109.04 Service Black Printhead

109.05 Service Black Printhead

109.08 Service Black Printhead

109.11Service Black Printhead

109.12 Service Black Printhead

109.13 Service Black Printhead

The black printhead failed to complete servo.

The black printhead mirror motors failed to achieve lock.

The black printhead mirror motors lost PLL motor lock.

Failure reading NVRAM from printhead.

The black laser showed bad in EMS testing.

Failure writing data to printhead Perform a POR. If the problem persists, go

Failure reading data from the printhead Perform a POR. If the problem persists, go

Printhead declared error Perform a POR. If the problem persists, go

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

Perform a POR. If the problem persists, go to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

to “Printhead service check” on

page 2-57.

122.xx Service Fuser Error

122.01 Service Fuser Error

122.02 Service Fuser Error

122.03 Service Fuser Error

122.04 Service Fuser Error

122.05 Service Fu

ser Er

ror

122.06 Service Fuser Error

930.09 Service LVPS

122.10 Service Fuser Error

122.11 Service Fuser Error

122.12 Service Fuser Error

Fuser error Go to “Fuser service check” on

EWC error—Attempting to print with estimated power at or below minimum power.

Fuser over temperature. Go to “Fuser service check” on

Fuser open thermistor check failed. Go to “Fuser service check” on

EWC Error—Did not reach EWC start temperature in time.

EWC Error—Did not change temperature within expected time.

EWC Error—Did not reach EWC stop temperature in time.

Fuser zero crossings out of range. Zero crossing detected.

Fuser failed to warm up. Go to “Fuser service check” on

Fuser under temperature error while in standby.

Fuser under temperature error while printing.

page 2-39.

Go to “Fuser service check” on

page 2-39.

Go to “Fuser service check” on

page 2-39

Go to “Fuser service check” on

page 2-39

Go to “Fuser service check” on

page 2-39

Go to “Fuser service check” on

page 2-39.

Go to “Fuser service check” on

page 2-39.

Go to “Fuser service check” on

page 2-39.

Diagnostic information 2-17

Page 62

7525-xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

122.13 Service Fuser Error

122.14 Service Fuser Error

122.15 Service Fuser Error

122.16 Service Fuser Error

122.17 Service Fuser Error

141.xx Service Staging Motor

141.01 Service Staging Motor

141.02 Service Staging Motor

141.03 Service Staging Motor

141.04 Service Staging Motor

141.05 Service Staging Motor

Fuser open thermistor check failed for second thermistor.

Fuser shorted thermistor check failed for hot roll thermistor.

Fuser started thermistor check failed for second thermistor

EWC Error—Estimated power is at or above maximum power.

Total failure to close fuser nip. Go to “Fuser service check” on

Staging motor error. Go to “90x.xx error” on page 2-31

Staging motor has exceeded the ramp up table.

Staging motor has exceeded number of encoders at min PWM.

Staging motor has exceeded number of encoders at max PWM.

Motor encoder count did not change between interrupts.

Staging motor has encountered a stall timeout.

Go to “Fuser service check” on

page 2-39.

Go to “Fuser service check” on

page 2-39.

Go to “Fuser service check” on

page 2-39.

Go to “Fuser service check” on

page 2-39.

Go to “90x.xx error” on page 2-31

150.xx Service Black/ITU cartridge Motor

150.01 Service Black/ITU cartridge Motor

150.02 Service Black/ITU cartridge Motor

150.03 Service Black/ITU cartridge Motor

150.04 Service Black/ITU cartridge Motor

150.05 Service Black/ITU cartridge Motor

150.06 Service Black/ITU cartridge Motor

150.07 Service Black/ITU cartridge Motor

Black/ITU Cartridge Motor Go to “Main drive gear assembly (EP

Failed to achieve lock for motor within allotted time.

Timeout waiting for SAP BLDC motor to reach valid FG speed.

Timeout waiting for MP_NUM_INITIAL_SAP_HALLS.

Timeout waiting for SAP BLDC motor FG.

Lost lock for motor. Go to “Main drive gear assembly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP

Motor stalled in time-based commutation.

drive) service check” on page 2-41.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

Go to “Main drive gear assembly (EP

e) service check” on page 2-41.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

2-18 Service Manual

Page 63

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

7525-xxx

152.xx Service CMY Cartridge Motor

152.01 Service CMY Cartridge Motor

152.02 Service CMY Cartridge Motor

152.03 Service CMY Cartridge Motor

152.04 Service CMY Cartridge Motor

152.05 Service CMY Cartridge Motor

152.06 Service CMY Cartridge Motor

152.07 Service CMY Cartridge Motor

8xx service errors

840.01 Scanner disabled

840.02 Scanner auto disabled

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

Failed to achieve lock for motor within allotted time.

Timeout waiting for SAP BLDC motor to reach valid FG speed.

Timeout waiting for MP_NUM_INITIAL_SAP_HALLS.

Timeout waiting for SAP BLDC motor FG.

Lost lock for motor. Go to “Main drive gear assembly (EP

Excessive SAP BLDC PWM. Go to “Main drive gear assembly (EP

Motor stalled in time-based commutation.

The scanner is disabled and can’t be used.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

Go to “Main drive gear assembly (EP

drive) service check” on page 2-41.

Enter the configuration menu, and reenable the scanner module. Go to “840.xx

service check” on page 2-63

This message is posted when the MFP PORs. Enter the configuration menu, and re-enable the scanner module. Go to

“840.xx service check” on page 2-63

841

842

843

843.01

844.yy

844

844.01

844.02

Image Pipeline Image pipeline ASIC. Go to “CCD service

Scanner Failure Communication failure. Go to “CCD

Scanner Failure Carriage mechanical failure.Go to

Scanner Failure ADF mechanical failure. Go to “ADF

Scanner Failure Lamp failure. Go to “CCD serv

Front scan module output level error Go to “CCD service check” on

Rear scan module output level error

Front scan module lamp level too low Front Mono channel, Front Color channels,

check” on page 2-65. Also,Go to “Flatbed home position service check” on page 2-66.

service check” on page 2-65

“Flatbed motor service check” on page 2-65

paper jam service check” on page 2-68

ice check”

on page 2-65

page 2-65

Front Red channel, Front Green channel, and/or Front Blue channel is detected to have low lamp level. Go to “CCD service

check” on page 2-65

Diagnostic information 2-19

Page 64

7525-xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

844.03

845.yy

845

845.01

845.02

Rear scan module lamp level too low Rear Mono channel, Rear Color channels,

Scanner Failure CCD failure

Front scan module cable failure or SCC card failure

Rear scan module cable failure or SCC card failure

Cable / SCC Failure Front scan module connector or cable

Rear Red channel, Rear Green channel, and/or Rear Blue channel is detected to have low lamp level. Go to “CCD service

check” on page 2-65

Go to “CCD service check” on

page 2-65

CCD channel failure. Check each channel(mono, R, G, B) for identical values indicating bad cable and/or SCC card. Excessive noise test for the dark data indicating some sort of CCD or analog electronics issue on that channel or channels.

Go to “CCD service check” on

page 2-65

Go to “CCD service check” on

page 2-65

failure Go to “CCD service check” on

page 2-65

845.03

845.04

846

846.01

846.02

846.03

846.04

846.05

Cable / SCC Failure Rear scan module connector or cable

failure Go to “CCD service check” on

page 2-65

Cable Failure The connector cable is defective.

Go to “CCD service check” on

page 2-65.

Front calibration strip unusable Go to “CCD service check” on

page 2-65

Rear calibration strip unusable

Front calibration strip too far left The font calibration strip is placed to high

or to low. Go to “CCD service check” on

page 2-65

Front calibration strip too far right Go to “CCD service check” on

page 2-65.

Front calibration strip has excessive skew

Front calibration strip has excessive bow

2-20 Service Manual

Page 65

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

7525-xxx

846.06

846.07

847

847.01

847.02

848

Front calibration strip has excessive dark area

Front magnification exceeds limits Rear excessive variability for Mono, Red,

Modem Failure The Configuration ID bit that describes the

Fax Storage The amount of flash storage available on

Fax Storage The devices’ flash partition is invalid or

Modem/Config ID Mismatch A device doesn’t have a modem installed,

Front excessive variability for Mono, Red, Green, or Blue. Go to “CCD service

check” on page 2-65

Green, or Blue. Go to “CCD service

check” on page 2-65

device’s modem doesn’t match the actual modem installed in the device.

the device is too small. Note: The NAND Flash partition can shrink as bit failures cause blocks to be invalidated. Go to

“Format Fax Storage” on page 3-34. If

the issue is not fixed, replace the controller board. Go to “Controller board removal”

on page 4-18.

unavailable. Go to “Format Fax Storage”

on page 3-34. If the issue is not fixed,

replace the controller board. Go to

“Controller board removal” on page 4-18.

even though its Configuration ID indicates that a modem should be present.

848.01

849

849.01

9xx service errors

900.xx Service RIP Software

902.xx Service Engine Software

903.xx Service Engine Software

904.xx Service Engine Software

905.xx Service Engine Software

906.xx Service Engine Software

Modem/Config ID Mismatch A device has a modem installed, but its

HD/Config ID Mismatch A device doesn’t have a hard drive

HD/Config ID Mismatch A device has a hard drive installed, but its

Unrecoverable RIP software error/ illegal trap.

A general engine software error. Go to “90x.xx error” on page 2-31

Configuration ID indicates that a modem shouldn’t be present.

installed, even though its Configuration ID indicates that a hard drive should be present.

Configuration ID indicates that a hard drive shouldn’t be present.

Go to “90x.xx error” on page 2-31.

Diagnostic information 2-21

Page 66

7525-xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

907.xx Service Engine Software

908.01 Service Engine Software?

908.02 Service Engine Software

908.03 Service Engine Software

908.04 Service Engine Software

925.01 Service Main Fan

929.xx Service Toner Sensor

930.xx Service LVPS

A general engine software error. Go to “90x.xx error” on page 2-31

Board level was not obtained.

Timeout waiting for bullet serial data to be updated.

NVM_OK was not received from NV2 server for successfully submitted request.

Over temperature condition detected.

Main fan stalled Go to “925.01—Fan error service check”

The printer doesn't register a transition on the toner sensor for a set period of time. Either the printer's toner sensor is faulty or its print cartridge is defective.

Low voltage power supply did not detect zero crossing.

on page 2-31

The Servicer should follow these steps to resolve this problem:

1. Use the base sensor test in Diagnostics mode to inspect the toner sensor's operation.

2. If the toner sensor is operating correctly, then the problem is the print cartridge.

Replace the LVPS. See “Low-voltage

power supply (LVPS) assembly” on page 4-43.

940.xxService Cyan TMC Sensor

941.xx Service Magenta TMC Sensor

942.xx Service Yellow TMC Sensor

943.xx Service Black TMC Sensor

948.xx Service Engine Card

949.xx Se Engi

rvice

ne Card

The cyan cartridge toner meter cycle (TMC) switch error.

.01 - Recoverable .02 - non recoverable

The magenta cartridge toner meter cycle (TMC) switch error.

.01 - Recoverable .02 - non recoverable

The yellow cartridge toner meter cycle (TMC) switch error.

.01 - Recoverable .02 - non recoverable

The black cartridge toner meter cycle (TMC) switch error.

.01 - Recoverable .02 - non recoverable

The pel clock check failed. If this error message persists, replace the

Delay line calibration failure If this error message persists, replace the

Go to “Toner sensors (Y, C, M, K) on

TMC card” on page 2-58

Go to “Toner sensors (Y, C, M, K) on

TMC card” on page 2-58

Go to “Toner sensors (Y, C, M, K) on

TMC card” on page 2-58

Go to “Toner sensors (Y, C, M, K) on

TMC card” on page 2-58

controller board. See “Controller board

removal” on page 4-18.

controller board. See “Controller board

removal” on page 4-18.

2-22 Service Manual

Page 67

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

7525-xxx

950.xx Service NVRAM Failure

951.xx Service NVRAM Failure

952.xx Service NVRAM Failure

953.xx Service NVRAM Failure

954.xx Service NVRAM Failure

955.xx Service Code CRC <loc>

There is a mismatch between controller EEPROM and mirror.

• 950.00 through 950.29 codes: mismatch between controller and mirror

• 950.30 through 950.60 codes: mismatch between secure and controller

Mismatch between controller EEPROM and mirror.

• 951.00 through 951.29 codes: mismatch between controller and mirror

• 951.30 through 951.60: mismatch between secure and controller

A recoverable MVRAM Cyclic Redundancy Check (CRC) error occurred. “n” is the offset at which the error occurred.

NVRAM chip failure with mirror.

The NVRAM chip failure with controller part.

The Code ROM or NAND flash failed the Cyclic Redundancy Check (CRC) check or the NAND experienced an uncorrectible multi-bit failure. “<loc>” indicates the source of the failure and has one of the following values:

• CRC Failure: The source is a failing package indicated by Pn where “n” is the package number. This error could occur on a controller with ROM or NAND flash and could occur as a result of the CRC check done when the machine is powered on. The range of package numbers is from 0 to

15.

• Error Correction Code (ECC) Failure: The source is a failing page indicated by Bn where “n” is the page number. This error occurs only if a multi-bit failure is detected during the ECC execution. Single bit failures will be corrected automatically and will not result in a service error. The range of page numbers is from 0 to 1023.

Go to “950.xx NVRAM failure service

check” on page 2-33.

Performing a POR will clear this error.

956.00 Service System Board

956.01 Service System Board

957.xx Service System Board

Controller board failure. Processor failure.

Processor over temperature.

Controller board failure. ASIC failure.

Replace conrtroller board. See“Con

board removal” on page 4-18.

Diagnostic information 2-23

oller

Page 68

7525-xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

958.xx Service NAND Failure

959.01 Service Invalid Firmware

959.02 Service Invalid Firmware

959.03 Service Invalid Firmware

959.04 Service Invalid Firmware

959.05 Service Invalid Firmware

959.20 Service System Board

959.21 Service System Board

959.22 Service System Board

Printer has performed more than 100 “shift and reflash” operations as a result of ECC bit corrections.

Controller verification failure of pensive boot code

Failure to authenticate Signature Verification Code.

Signature verification Code failure to authenticate a code partition.

Jump to unverified address. Update firmware or replace controller

Unknown Boot Failure. Update firmware or replace controller

System hardware failure. Replace controller board. See“Controller

System did not respond to command request.

Challenge Secret Failure. ASIC/SP mismatch

Update firmware or replace controller board. See“Controller board removal”

on page 4-18.

Update firmware or replace controller board. See“Controller board removal”

on page 4-18.

Update firmware or replace controller board. See“Controller board removal”

on page 4-18.

board. See“Controller board removal”

on page 4-18.

board. See“Controller board removal”

on page 4-18.

board removal” on page 4-18.

Replace controller board.

Replace controller board. See“Controller

board removal” on page 4-18.

959.23 Service System Board

959.24 Service System Board

959.25 Service System Board

959.26 Service System Board

959.27 Service System Board

959.28 Service System Board

960.xx Service Memory Error

961.xx Service Memory Failure

962.xx Service Memory Failure

System self test failure during initialization.

EEPROM Retention Error (write failure) Replace controller board. See“Controller

Insufficient device space during hardware programming.

Incremental counter reset exceeds maximum value.

Increment count failed due to ma

mum value limit.

Invalid SP memory configuration. Replace controller board. See“Controller

RAM memory error: RAM soldered on the board is bad.

RAM memory error: slot 1 RAM is bad. Check RAM. If RAM is ok, replace the

RAM memory error: slot 2 RAM is bad. Check RAM. If RAM is ok, replace the

Replace controller board. See“Controller

board removal” on page 4-18.

Replace controller board. See“Controller

board removal” on page 4-18.

Replace controller board. See“Controller

board removal” on page 4-18.

Replace controller board. See“Controller

board removal” on page 4-18.

Replace controller board. See“Controller

board removal” on page 4-18.

controller. See“Controller board

removal” on page 4-18.

controller. See“Controller board

removal” on page 4-18.

2-24 Service Manual

Page 69

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

7525-xxx

964.xx Service Emulation Error

975.xx Service Standard Network

975.xx Service Network Card x

976.xx Service Standard Network

976.xx Service Network Card x

978.xx Service Standard Network

978.xx Service Network Card x

Download emulation cyclic redundancy check (CRC) failure has occurred. A checksum failure detected in the emulation header or emulation file.

Network error: unrecognizable network port.

Unrecoverable software or error in network or network port.

Bad checksum while programming network port.

The following actions may be taken:

1. Disable the Download Emulation.

2. Program the download emulation into the code overlay SIMM again.

3. If the problem is not resolved replace the code overlay SIMM, and download emulation again.

Replace the standard network card or the card in the specified slot.

If unable to clear the error message, check the following:

• If installed, check network card for correct installation.

• If correctly installed, replace the network card.

• If a network card is not installed, replace the controller board.

Check the following:

• Make sure you have downloaded the code in binary mode, not ASCII.

• Reprogram the Network card.

• If the problem persists, and if installed, check the network card for correct installation.

• If correctly installed, replace the network card.

If a network card is not installed, replace the controller board.

979.xx Service Standard Network

979.xx Service Network Card x

982.xx Service <device> Comm.

Flash parts failed while programming the network port

Communications error detected by the specified device.

Note: <device

oll

owing:

• Duplex unit

•Tray 2

•Tray 3

> can be one of the

Check the following:

• If installed, check the network card for correct installation.

• If correctly installed, replace the network card.

• If a network card is not installed, replace the controller board.

Diagnostic information 2-25

Page 70

7525-xxx

Service error messages (1XX, 8XX and 9xx) (continued)

Error code Description Action

990.xx Service <device>

This error message indicates that an equipment check condition has occurred in the specified device, but the device is unable to identify the exact component failure.

Note: <device> can be one of the following:

• Duplex option.

•Tray2

•Tray 3

2-26 Service Manual

Page 71

Fax error log codes

Error code Description Action

7525-xxx

000

200 Error occurred when transmitting

3XX Error occurred when receiving

4XX Error occurred when sending

5XX Received unknown response from

6XX Error occurred when receiving a frame. • Check line quality.

7XX Error occurred when sending a frame. • Check line quality.

No error occurred during fax transmission

training.

image data.

remote fax device.

No action needed

• Check line quality.

• Select a lower ‘Max Speed’.

• value under Fax Send settings

• Adjust the transmit level.

• Check line quality.

• Adjust ‘Receive Threshold’.

• Select a lower ‘Max Speed’ value under Fax Receive settings.

• Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’ value under Fax Receive settings.

No action needed. Issue is with the other device.

• Adjust ‘Receive Threshold’.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’ value under Fax Send settings.

800 Received EOT unexpectedly from

the modem in V34 mode.

802 Too many timeouts occurred

during ECM reception.

803 Fax cancelled by user No action needed.

804 Unexpectedly received a disconnect

command from the remote end.

805 Remote fax device failed to respond to

the DCS command.

808 T1 timeout occurred when trying to

establish a connection with a remote fax device.

809 T2 Timeout occurred due to loss of

command/response synchronization.

• If error persists disable V34 modulation scheme.

• If error persists disable ECM mode.

• Check line quality.

• Adjust Transmit Level/Receive Threshold values.

• Remote device could be requesting an unsupported feature.

• Adjust Transmit Level/Receive Threshold values.

• Remote device could be malfunctioning.

• Adjust Transmit Level/Receive Threshold values.

Diagnostic information 2-27

Page 72

7525-xxx

Fax error log codes (continued)

Error code Description Action

80A T5 Timeout occurred when transmitting

image data to remote fax device.

80B Too many errors when transmitting in

ECM mode.

80C Remote device failed to respond to the

CTC command.

80D Received too many requests from

remote end to repeat the previous command sent.

80E Functional limitation- Remote fax

device does not support G3 receive capability.

811 Failed to detect a fax device at the

remote end.

812 No more data rates available in V34

modulation scheme.

• Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’value under Fax Send settings.

• Check line quality.

• Adjust ‘Transmit Level’.

• Select a lower ‘Max Speed’value under Fax Send settings.

• Select a lower ‘Max Speed’ value under Fax Send settings.

• Adjust ‘Transmit Level’.

• Check line quality.

• Adjust ‘Transmit Level’.

• Check if line conditions on remote end will facilitate a good connection.

No action needed. Issue with the remote device.

• Verify MFD is answering to fax call and not a voice call.

• Decrease value of ‘Rings To Answer’ setting.

• Adjust to a lower modulation scheme.

813 Timeout occurred after waiting too long

to receive a good frame.

814 Tried too many times at selected speed

using V34 modulation scheme.

815 Fax transmission was interrupted due

to power failure.

818 Fax transmission failed due to

insufficient memory to store scanned image.

819 Fax transmission failed due to

insufficient memory to store received image.

81A A timeout occurred during transmission

of a page in ECM mode.

880 Failure to transmit training successfully

in V17, V29, V27 terminal modulation schemes.

881 Failure to transmit training successfully

in V33, V29, V27 terminal modulation schemes.

• Adjust “Receive Threshold”.

• Adjust ‘Transmit Level’.

• Adjust to a lower modulation scheme.

• Troubleshoot MFP if error persists. See

“Modem / fax card service check” on page 2-71.

Adjust ‘Memory Use’ setting to allocate more memory for send jobs.

Adjust ‘Memory Use’ setting to allocate more memory for receive jobs.

Select a lower ‘Max Speed’ value under Fax Send settings.

• Select a lower “Max Speed” under Fax Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

2-28 Service Manual

Page 73

Fax error log codes (continued)

Error code Description Action

7525-xxx

882 Failure to transmit training successfully

in V17, V29 terminal modulation schemes.

883 Failure to transmit training successfully

in V17,V27 terminal modulation schemes.

884 Failure to transmit training successfully

in V29, V27 terminal modulation schemes.

885 Failure to transmit training successfully

in V17terminal modulation scheme.

886 Failure to transmit training successfully

in V29 terminal modulation scheme.

887 Failure to transmit training successfully

in V27 terminal modulation scheme.

• Select a lower “Max Speed” under Fax Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

• Select a lower “Max Speed” under Fax Send settings.

• Adjust the “Transmit Level”.

• Check line quality.

888 Failure to transmit training successfully

at 2400 bps in V27 terminal modulation scheme.

889 Failed to connect at the minimum

speed supported by the MFP.

88A Failed to connect using V.34

modulation scheme.

901 No fax tones detected from remote

end.

902 No dial tone detected. • Check by enabling ‘Behind a PABX’

903 Busy tone detected. Check with remote end if successive

904 Hardware error detected. See “Modem / fax card service check”

905 A timeout occurred after dialing the

number and waiting for a response.

• Adjust “Transmit Level”.

• Check line quality.

• Adjust “Transmit Level”.

• Incompatible connection.

• Check line quality.

• Adjust to a lower modulation scheme.

• Adjust Transmit Level Receive Threshold values.

• Verify destination phone number.

• Verify that the remote fax is authorized to receive faxes.

setting.

• Check phone line.

• Check MFD modem hardware.

attempts fail.

on page 2-71.

Check with remote end if successive attempts fail.

906 Fax cancelled by user. No action needed.

Diagnostic information 2-29

Page 74

7525-xxx

Fax error log codes (continued)

Error code Description Action

907 Modem detected a digital line

connection.

908 Phone line was disconnected Restore phone line connection.

A00 Received request for unsupported

function from remote fax device.

A01 Received request for unsupported

image width from remote fax device.

A02 Received request for unsupported

image resolution from remote fax device.

A03 Received request for unsupported

compression type from remote fax device.

A04 Received request for unsupported

image length from remote fax device.

F00 Unknown error occurred. No action needed.

Verify the MFP is connected to an analog line. See“Fax transmission service

check” on page 2-72.

No action needed.

2-30 Service Manual

Page 75

Service checks

JFAN1

Pin Voltage

1 +3.3 V dc 2 Ground 3 +24 V dc

90x.xx error

Step Questions / actions Yes No

7525-xxx

1 Turn the printer off, and remove the rear shield.

See “Rear shield removal” on page 4-7. Check the cable connections.

Are all the cable connections secure?

Replace the controller board. See “Controller

board removal” on page 4-18.

Securely make all the connections. POR the printer.

925.01—Fan error service check

Step Questions / actions Yes No

1 Turn off the printer, and remove the rear shield.

See “Rear shield removal” on page 4-7. Unplug the fan cable at JFAN1 and turn the printer on. Check the following connectors:

Are the measured values correct?

Replace the top cover (which includes the fan). See “Top cover assembly

removal” on page 4-9.

Replace the controller board. See “Controller

board removal” on page 4-18.

Diagnostic information 2-31

Page 76

7525-xxx

JMIRR1

Pin Volt.

(V dc)

23.3 35 4GND 524

Printhead service check

Error code Color

106.xx Yellow

107.xx Cyan

108.xx Magenta

109.xx Black

Step Questions / actions Yes No

1 Turn the printer off, and remove the rear shield.

See “Rear shield removal” on page 4-7. Check the cables connected at JMIRR1 and JPH1 on the controller board. Check for damage.

Are the cables damaged?

Turn the printer on, and verify the following

values at JMIRR1:

Are the values approximately correct?

Replace the printhead. See

“Printhead removal” on page 4-56.

Replace the printhead. See

“Printhead removal” on page 4-56.

Go to step 2.

Replace the controller board. Replace the controller board. See

“Controller board removal” on page 4-18.

2-32 Service Manual

Page 77

950.xx NVRAM failure service check

Warning: Replace one of the following components, and perform a POR before replacing a second

component. Never replace both of the components without performing a POR after installing each one, or the printer will be rendered inoperable:

• Operator panel assembly

• Controller board

Warning: Never install and remove components listed above as a method of troubleshooting components.

Once a component has been installed in a printer, and the printer is powered on, it cannot be used in another printer. It must be returned to the manufacturer.

This error code indicates a mismatch between the operator panel assembly and the controller board.

Step Questions / actions Yes No

7525-xxx

1 Have any updates been made to the firmware? Reload the firmware and try

Did reloading the firmware correct the

problem?

again. Go to step 2.

Problem resolved. Replace the controller board

Replace the controller board with a new, and not previously installed controller board. See

“Controller board removal” on page 4-18.

with a new, and not previously installed controller board. See

“Controller board removal” on page 4-18.

Autocompensator mechanism service check

Note: The input (S2) sensor is part of the autocompensator mechanism (ACM), and is not available separately.

Step Questions / actions Yes No

1 Turn the printer off, and then remove the rear

shield. See “Rear shield removal” on

page 4-7. Check the cable at JSP1 on the

controller board for proper connection. Is the cable properly connected?

Did the printer function correctly after

reconnecting the cables?

Go to step 3. Properly connect the cables,

and POR the printer. Go to step 2.

Problem resolved. Go to step 3.

Diagnostic information 2-33

Page 78

7525-xxx

JSP1

Pin Value

2 +24 V dc 4 +24 V dc 5 +5V (when paper is picked) 7 Ground

8 Ground 10 +5 V dc 12 _5 V dc (when paper is picked) 15 +5 V dc 16 Ground

JBIN1

Pin Value

1 > 0 V dc, +5V dc during

cycle

2 +3.3 V dc beam blocked

0 V dc unblocked

3 Ground

Step Questions / actions Yes No

Turn the printer on, and then verify the

following approximate values at JSP1:

Are the values approximately correct?

Replace the autocompensator mechanism. See

“Autocompensator mechanism (ACM)—standard tray removal” on page 4-12.

Replace the controller board. See “Controller

board removal” on page 4-18.

Bin full sensor service check

Step Questions / actions Yes No

1 Inspect the bin full sensor located towards the

rear of the top cover assembly. Is the bin full sensor dislodged or damaged?

Repair or replace the bin full sensor. See“Bin full

sensor” on page 4-15.

Go to step 2.

With the scanner assembly in the down

position, perform the standard bin sensor base sensor test. See “Base Sensor Test” on

page 3-18.Toggle the bin full flag attached to

the rear shaft of the redrive unit. Does the flag rotate freely and interrupt the

sensor beam when in normal position?

Turn the printer off, and remove the rear shield.

See “Rear shield removal” on page 4-7. Turn the printer on, and then check the values below at JBIN1:

2-34 Service Manual

Are the values correct?

Go to step 3. Reposition or replace the

flag. If the flag is broken, replace the bin full flag. See“Bin full flag removal”

on page 4-103.

Problem resolved. Replace the controller

board. See.“Controller

board removal” on page 4-18

Page 79

Dead printer service check

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.

JLVPS1 (exposed conductors)

Pin Value Pin Value

1 +5 V dc 2 Ground

3 +5 V dc 4 Ground

5 +5 V dc 6 Ground

7 +24 V dc 8 Ground

9 +24 V dc 10 Ground 11 +24 V dc 12 Ground

16 Ground

A dead printer is a condition where the display is blank, the LED on the operator panel is off, the fan does not turn, no motors turn, and the fuser does not heat.

If a 650-sheet Duo Drawer is installed, remove the option and check the base printer for correct operation. If the base printer operates correctly, replace the 650-sheet Duo Drawer.

Warning: Observe all necessary ESD precautions when removing and handling the controller board or any

installed option cards or assemblies. See “Handling ESD-sensitive parts” on page 4-1.

Remove any input paper handling options from the printer.

Step Questions / actions Yes No

7525-xxx

1 Check the AC line voltage.

Is the line voltage correct?

Is the AC line cord damaged? Replace the line cord. Go to step 3.

Is the JLVPS1 cable correctly connected at

JLVPS1 on the controller board?

Turn the printer off, and then on.

Does the problem persist?

Warning: Damage to the printer is possible.

Be careful to touch only one conductor at a time. Rest the probe against the connector to steady it.

With the printer on.verify the following values at JLVPS1:

Go to step 2. Inform the customer.

Go to step 5. Reconnect the JLVPS1

Go to step 5. Problem resolved.

Replace the controller board. See “Controller

board removal” on page 4-18.

cable, and go to step 4.

Replace the LVPS. See“Low-voltage power

supply (LVPS) assembly” on page 4-43.

Are the values approximately correct?

Diagnostic information 2-35

Page 80

7525-xxx

JFUSES1

Pin Value

8 Ground

9 +3.3 V dc

Duplex/manual feed sensor (S1) service check

Note: Before performing this service check, ensure that the printer is on a hard level surface.

Step Questions / actions Yes No

1 Enter Diagnostics Menu (turn the printer off,

press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).

Perform the Base Sensor Test. See “Base

Sensor Test” on page 3-18.

1. Select Base Sensor Test, and press Select ().

2. Select S1, and press Select ().

3. Install tray 1.

Does the display indicate InputS1—Media Clear…?

Pull tray 1 out.

Does the display indicate InputS1—Media Present…?

Remove the tray, and inspect sensor.

Is there something obstructing the sensor?

Inspect the spring-loaded shaft/flag in the tray.

The flag portion of the shaft intercepts the sensor, except when a sheet is being staged for duplexing.

Does the shaft rotate freely and return to home position (flag at top of rotation)?

Is the flag on the shaft broken? Replace the tray. Go to step 6.

Go to step 2. Go to step 4.

The sensor is functioning correctly.

Remove the obstruction and restart the test.

Go to step 5. Replace the tray with a new

Go to step 3.

Go to step 4.

one.

Is the cable correctly connected to JFUSES1

on the controller board and to the sensor. Is the sensor cable properly connected?

Turn the printer off, and remove the rear shield.

See “Rear shield removal” on page 4-7. Turn the printer on, and check the values at JFUSES1:

Are the values approximately correct?

2-36 Service Manual

Go to step 7. Reconnect the cable.

If the problem persists, go to step 7.

Replace the duplex sensor. See “Duplex sensor

removal” on page 4-23.

Replace the controller board. See “Controller

board removal” on page 4-18.

Page 81

Front door sensor or switches service check

JINT1 JCVR1

Pin Value Pin Value

1 +5 V dc 1 +24 V dc 2 Ground

Step Questions / actions Yes No

7525-xxx

1 Enter Diagnostics Menu (turn the printer off, press

and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).

Perform the Base Sensor Test. See “Base Sensor

Test” on page 3-18.

1. Select Base Sensor Test, and press Select

().

2. Select Front Door, and press Select ().

3. Open and close the front door, and observe the display.

Does the display indicate Va l u e Cl os ed with the door closed and Value Opened with the door opened?

Open the front door and check the thin, tall, plastic

web (pivot plate) at the top right of the printer. With the other covers in place and closed, this web interacts with switches in the door.

Open the toner cover and check the motion of the web. Is the web loose, damaged, or missing?

Open the toner door and inspect the vertical web that

pushes and rotates the pivot plate. Is it damaged?

With the front cover open, inspect the two switches.

Using a tool, such as a spring hook, push the metal arms to check the movement.

Is there any damage to the switches or the surrounding area?

Sensor, toner door, and right doors are OK.

Replace the right cover assembly. See“Right

cover removal” on page 4-7.

Replace the top cover assembly. See “Top

cover assembly removal” on page 4-9.

Replace the right cover assembly. See“Right

cover removal” on page 4-7.

Go to step 2.

Go to step 3.

Go to step 4.

Go to step 5.

Turn the printer off, and remove the rear shield. See

“Rear shield removal” on page 4-7. Turn the

printer on, and verify the following values at JINT1 and JCVR1:

Are the values approximately correct?

Close the front cover and the toner door. Be sure the

right cover is in place. Turn the printer off, and then disconnect the cables at JINT1 and JCVR1. Test continuity at the connector under the following conditions:

• With front cover and toner door closed:

• With one or both doors open:

Are the tests verified?

Test pin 1 and pin 3 at JINT1 cable end and pin 1 and pin 2 at JCVR1 cable end.

Pin 2 and 3 at JINT1 cable end should indicate continuity, but Pin 1 and 2 at JCVR1 should have no continuity.

Go to step 6. Replace the controller

Contact your next level of support.

board. See “Controller

board removal” on page 4-18.

Replace the front cover assembly. See “Front

cover assembly removal” on page 4-2.

Diagnostic information 2-37

Page 82

7525-xxx

JBIN1

Pin Value

4 0 V dc +5V dc during cycle 5 +0 V dc (unblocked), +3.3 V dc

(unblocked)

6 Ground

Fuser exit sensor service check

Step Questions / actions Yes No

1 Enter Diagnostics Menu (turn the printer off,

press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).

Perform the Base Sensor Test. See “Base

Sensor Test” on page 3-18.

1. Select Base Sensor Test, and press Select ().

2. Select Fuser Exit Sensor, and press Select ().

3. Open and close the front door, and inspect the fuser exit sensor located on the LVPS shield.

Is the sensor dislodged or damaged?

Rotate the flag (paper diverter) in and out of

the sensor. Does the display indicate Media Clear and

Media Present with the cycle?

Does the flag rotate freely, but returns to block

the sensor?

Is the cable correctly connected to JBIN1 on

the controller board and to the sensor. is the sensor properly connected?

Correct the sensor or replace it. See “” on

page 4-28.

Sensor is good. Go to step 3.

Go to step 4. Replace the fuser.

Go to step 5. Reconnect the cable.

Go to step 2.

See“Fuser assembly

removal” on page 4-25.

Make sure the printer is turned off. Disconnect

the cable at the sensor and at JBIN1 on the controller board. Turn the printer on and check the voltage values:

Does the voltage values correct?

Replace the fuser exit sensor. See “” on

page 4-28.

Replace the controller board. See “Controller

board removal” on page 4-18.

2-38 Service Manual

Page 83

Fuser service check

JFUSES1

Pin Value

1 +24 V dc (doors closed) 2 +24 V dc (doors closed) 3 +24 V dc (doors closed) 4 +24 V dc (doors closed) 5 Between 0.6 and 3.28 V dc 6 Ground

8 Ground 10 Between -3 and +3.3 V dc 11 Ground (no wire

Step Questions / actions Yes No

7525-xxx

1 Some low-voltage power supply FRUs have a

voltage selector switch. If it does, the switch needs to be set to the correct voltage for your area

Has the LVPS been changed?

Turn the printer off, and remove the rear shield.

See “Rear shield removal” on page 4-7. Check the cable at JFUSES1 for proper connection to the controller board, the cable for pinch points, and the cable or connector for any other damage.

Is the cable damaged?

Check the connector JLVPS1 for proper

connection to the controller board, the cable for pinch points, and the cable or connector for any other damage.

Is the cable damaged?

Check the switch on the side of the LVPS to verify the correct voltage is set.

Replace the fuser cable. Go to step 3.

Repair or replace the LVPS cable. See “Low-voltage

power supply (LVPS) assembly” on page 4-43.

Go to step 2.

Go to step 4.

Check the power cable on the left side of the

fuser and the thermistor cables and connections on the right side of the fuser.

Are the cables or connectors damaged?

Disconnect the cable at JFUSES1 on the

controller board, and check the following voltages:

Are the values approximately correct?

Repair the cables. If the cables cannot be repaired, replaced the fuser. See

“Fuser assembly removal” on page 4-25.

Go to step 6. Replace the controller

Go to step 5.

board. See “Controller

board removal” on page 4-18.

Diagnostic information 2-39

Page 84

7525-xxx

Step Questions / actions Yes No

Replace the fuser. See “Fuser assembly

removal” on page 4-25.

Does the error clear?

Problem resolved. Replace the controller

board. See “Controller

board removal” on page 4-18.

Input sensor (S2) service check

The Input sensor (S2) is part of the autocompensator FRU and is not available otherwise.

Step Questions / actions Yes No

1 Enter Diagnostics Menu (turn the printer off,

press and hold and , turn the printer on, and then release the buttons when the installed memory and processor speed displays).

Perform the Base Sensor Test. See “Base

Sensor Test” on page 3-18.

1. Select Base Sensor Test, and press Select ().

2. Select S2, and press Select ().

3. Pull tray 1 out, and rotate the S2 sensor flag (S2 is located in front of the center autocompensator mechanism housing.) It should rotate freely and return to its original position.

Is the input (S2) sensor flag damaged?

Replace the autocompensator mechanism. See

“Autocompensator mechanism (ACM)—standard tray removal” on page 4-12.

Go to step 2.

Watch the display while rotating the flag.

Does the display indicate Media Clear and Media Present?

Turn the printer off, and remove the rear shield.

See “Rear shield removal” on page 4-7. Is the JSP1 cable connector properly

connected to the controller board?

Turn the printer on, and check the voltage at

JSP1 pin 15. Is the voltage approximately +5 V dc?

Problem resolved. Go to step 3.

Go to step 4. Reseat the connector.

Replace the autocompensator mechanism. See

“Autocompensator mechanism (ACM)—standard tray removal” on page 4-12.

Replace the controller board. See “Controller

board removal” on page 4-18.

2-40 Service Manual

Page 85

Main drive gear assembly (EP drive) service check

JCARTB1

Pin Voltage

4 +24 V dc 6 +24 V dc 8 +24 V dc

9 Ground 12 Ground 13 +24 V dc 15 +24 V dc 17 +24 V dc

Step Questions / actions Yes No

7525-xxx

1 Turn the printer off, and remove the rear shield.

See “Rear shield removal” on page 4-7. Check the cable at JCARTB1 for proper connection to the controller board, the cable for pinch points, and the cable or connector for any other damage.

Is the cable damaged?

Disconnect the cable at JCARTB1 on the

controller board, and verify the following values.

Are the voltages correct?

Replace the main drive assembly. See “Main

drive gear assembly with motor removal” on page 4-53.

Does the error clear?

Replace the JCARTB1 cable.

Go to step 3. Replace the controller

Problem resolved. Replace the controller

Go to step 2.

board. See “Controller

board removal” on page 4-18.

board. See “Controller

board removal” on page 4-18.

Diagnostic information 2-41

Page 86

7525-xxx

JOPP1

Pin Voltage

2 +5 V dc

4 Ground

5 +5 V dc

6 +3.3 V dc

7 Ground

Operator panel service check

Warning: Replace one of the following components, and perform a POR before replacing a second

component. Never replace both of the components without performing a POR after installing each one, or the printer will be rendered inoperable:

• Operator panel assembly

• Controller board

Warning: Never install and remove components listed above as a method of troubleshooting components.

Once a component has been installed in a printer, and the printer is powered on, it cannot be used in another printer. It must be returned to the manufacturer.

One or more operator panel buttons fail

Step Questions / actions Yes No

1 Run the Button Test. See “Button Test” on

page 3-13 in Diagnostics Menu.

Did any of the buttons fail the test?

Turn the printer off, and remove the rear shield.

“Rear shield removal” on page 4-7.

Disconnect the operator panel assembly cable at JOPP1 on the controller board. Turn on the printer, and verify the following voltages:

Are the voltage values approximately correct?

Replace the operator panel assembly. See “Operator

panel removal” on page 4-98.

Replace the operator panel. See “Operator panel

removal” on page 4-98.

If the problem is not resolved, replace the operator panel cable. See

“Op panel cable” on page 4-101

Go to step 2.

Replace the controller board. See “Controller

board removal” on page 4-18.

Operator panel display blank, five beeps

Service tip: The printer has detected a problem with the controller board, the operator panel assembly cable (part of the front cover assembly), or the operator panel assembly if POST does not complete. The printer emits five beeps, and sticks in a continuous pattern until the printer is turned off.

2-42 Service Manual

Step Questions / actions Yes No

1 Is the operator panel assembly cable properly

installed at controller board JOPP1 and at the operator panel assembly?

Go to step 2. Reinstall the cable.

Page 87

Step Questions / actions Yes No

JOPP1

Pin Voltage

2 +5 V dc

4 Ground

5 +5 V dc

6 +3.3 V dc

7 Ground

JOPP1

Pin Voltage

10 V dc

2 +5 V dc

30 V dc

4 Ground

5 +5 V dc

6 +3.3 V dc

7 Ground

7525-xxx

Turn the printer off, and remove the rear shield.

See “Rear shield removal” on page 4-7. Disconnect the operator panel assembly cable at JOPP1 on the controller board. Turn on the printer, and verify the following voltages:

Are the voltage values approximately correct?

Check continuity of the operator panel

assembly cable. Is there continuity?

Go to step 3. Replace the controller

Replace the operator panel assembly. See “Operator

panel removal” on page 4-98.

board. See “Controller

board removal” on page 4-18.

Replace the operator panel cable. See “Op panel

cable” on page 4-101

Operator panel display blank, printer beeps five times and pauses

Step Questions / actions Yes No

1 Turn off the printer, and remove the rear shield.

See “Rear shield removal” on page 4-7. Disconnect the cable at JOPP1 on the controller board. Verify the following values:

Go to step 2. Replace the controller

board. See “Controller

board removal” on page 4-18.

Are all these values approximately correct?

Check for continuity in the operator panel cable

connector. Do all the conductors indicate continuity?

Replace the operator panel. See “Operator panel

removal” on page 4-98.

Replace the operator panel cable. See “Op panel

cable” on page 4-101

Diagnostic information 2-43

Page 88

7525-xxx

JOPP1

Pin Voltage

10 V dc

2 +5 V dc

30 V dc

4 Ground

5 +5 V dc

6 +3.3 V dc

7 Ground

JOPP1

Pin Voltage

10 V dc

2 +5 V dc

30 V dc

4 Ground

5 +5 V dc

6 +3.3 V dc

7 Ground

Operator panel displays all diamonds, no beeps

Step Questions / actions Yes No

1 Turn off the printer, and remove the rear shield.

See “Rear shield removal” on page 4-7. Disconnect the cable at JOPP1 on the controller board. Verify the following values:

Are all these values approximately correct?

Check for continuity in the operator panel cable

connector. Do all the conductors indicate continuity?

Go to step 2. Replace the controller

Replace the operator panel. See “Operator panel

removal” on page 4-98.

board. See “Controller

board removal” on page 4-18.

Replace the operator panel cable. See “Op panel

cable” on page 4-101

Operator panel displays all diamonds, five beeps

Step Questions / actions Yes No

2-44 Service Manual

1 Turn off the printer, and remove the rear shield.

See “Rear shield removal” on page 4-7. Disconnect the cable at JOPP1 on the controller board. Verify the following values:

Are all these values approximately correct?

Check for continuity in the operator panel cable

connector. Do all the conductors indicate continuity?

Go to step 2. Replace the controller

Replace the operator panel. See “Operator panel

removal” on page 4-98.

board. See “Controller

board removal” on page 4-18.

Replace the operator panel cable. See “Op panel

cable” on page 4-101

Page 89

Operator panel display is dim and unchanging

JOPP1

Pin Voltage

10 V dc

2 +5 V dc

30 V dc

4 Ground

5 +5 V dc

6 +3.3 V dc

7 Ground

Step Questions / actions Yes No

7525-xxx

1 Turn off the printer, and remove the rear shield.

See “Rear shield removal” on page 4-7. Disconnect the cable at JOPP1 on the controller board. Verify the following values:

Are all these values approximately correct?

Check for continuity in the operator panel cable

connector. Do all the conductors indicate continuity?

Go to step 2. Replace the controller

Replace the operator panel. See “Operator panel

removal” on page 4-98.

board. See “Controller

board removal” on page 4-18.

Replace the operator panel cable. See “Op panel

cable” on page 4-101.

Op panel USB cable service check

Step Questions / actions Yes No

1 Check the op panel USB cable for continuity.

Is there continuity?

Replace the controller board. See “Controller

board removal” on page 4-18

Replace the Op panel USB cable.

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 “Controller

board removal” on page 4-18.

There is an issue with the host machine.

Diagnostic information 2-45

Page 90

7525-xxx

Networking service check

Note: Before starting this service check, print out the network setup page. This page is found under Menu Reports - Network Settings. Consult the network administrator to verify that the physical and wireless network settings displayed on the network settings page for the device are properly configured. If a wireless network is used, verify that the printer is in range of the host computer or wireless access point, and there is no electronic interference. Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. For more network troubleshooting information, consult the Lexmark Network Setup Guide.

Step Questions / actions Yes No

1 If the device is physically connected to the

network, verify that the ethernet cable is properly connected on both ends.

Is the cable properly connected?

Connect the ethernet cable.

Did this fix the problem?

Check the printer’s online status under Printers

and Faxes on the host computer. Delete all print jobs in the print queue.

Is the printer online and in a Ready state.

Change the printer status to online.

Did this fix the issue?

Does the IP address displayed on the network

settings page match the IP address in the port of the drivers using the printer?

Does the LAN use DHCP?

Note: A printer should use a static IP

address on a network.

Are the first two segments if the IP address

169.254?

POR the printer.

Is the problem resolved

Go to step 3. If the network is wireless,

got to step 3.

Problem resolved Go to step 3.

Go to step 5. Go to step 4.

Problem resolved. Go to step 5.

Go to step 10. Go to step 6.

Go to step 7. Go to step 9.

Go to step 8. Go to step 9

Problem resolved Go to step 10.

Go to step 2.

Reset the address on the printer to match the

IP address on the driver. Did this resolve the issue?

Have the network admin verify that the printer

and PC’s IP address have identical subnet addresses.

Are the subnet addresses the same?

Using the subnet address supplied by the

network admin, assign a unique IP address to the printer.

Note: The printer IP address should match the IP address on the printer driver.

Did this fix the problem?

Is the device physically connected (ethernet

cable) to the network?

2-46 Service Manual

Problem fixed. Go to step 10.

Go to step 12. Go to step 11.

Problem resolved. Go to step 12.

Go to step 13. Go to step15.

Page 91

Step Questions / actions Yes No

7525-xxx

Try using a different ethernet cable.

Did this remedy the situation?

Have the network administrator check the

network drop for activity. Is the drop functioning properly?

Is the printer on the same wireless network as

the other devices?

Assign the correct wireless network to the

printer. Did this fix the problem?

Are the other devices on the wireless network

communicating properly?

Verify that the wireless card is properly seated

on the controller board. Is the wireless card seated correctly?

Properly reseat the wireless card.

Did this fix the problem?

Is the antenna damaged? Go to step 22. Go to step 21.

Replace the antenna.

Did this fix the problem?

Problem resolved Go to step 14.

Replace the controller board. Go to “Controller

board removal” on page 4-18

Go to step 17. Go to step 16.

Problem resolved Go to step 17.

Go to step 18. Contact the network

Go to step 20. Go to step 19.

Problem resolved. Go to step 20.

Problem resolved Go to step 22.

Contact the network administrator.

administrator.

Verify that the antenna is properly connected

to the wireless card. Is it connected correctly?

Properly connect the antenna.

Did this fix the problem?

Check pin 6 for +3.3V, and Pin 5 for +5V. on

connector JUSBW1 of the controller board. Pin 1 and 4 are GND.

Are the voltages and GNDs correct?

Go to step 24. Go to step 23.

Problem resolved Go to step 24.

Replace the wireless card. Go to “Wireless network

card” on page 4-71

Replace the controller board. Go to “Controller

board removal” on page 4-18

Diagnostic information 2-47

Page 92

7525-xxx

Print quality service check

Note: This symptom may require replacement of one or more CRUs (Customer Replaceable Units) designated as supplies or maintenance items, which are the responsibility of the customer. With the customer's permission, you may need to install a developer (toner) cartridge or photo conductor unit.

Service tip

Before troubleshooting any print quality problems, do the following:

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

replaced. To print a menu settings page:

a. press Menu ( ) on the operator panel. b. Select Reports from the Admin Menu, and press Select (). c. Select Menu Settings, and press Select ().

Note: Be sure and keep the original menu page to restore the customer's custom settings if needed.

2. On the menu page, make sure the following is set to the default level: – Color Correction: Set to Auto. – Print Resolution: Set to 1200 dpi (print quality problems should be checked at different resolution

settings).

– Toner Darkness: Set to 4 (default). – Color Saver: Set to OFF. – RGB Brightness, RGB Contrast, RGB Saturation: Set to 0. – Color Balance: Select Reset Defaults to zero out all colors. – Check the paper type, texture and weight settings against what is loaded in the printer.

Once the printer has been restored to its default levels, do the following:

1. Inspect the imaging unit for damage, including the developers and toner cartridges. Replace if damaged.

2. If paper other than 20lb plain letter/A4 paper is being used, load 20lb plain letter/A4.

3. Print the Print Quality pages to see if the problem remains. Look for variations in the print from what is

expected. To print the print Quality pages

a. Enter Diagnostics (turn off the printer, press and hold Left ( ) and Select ( ), turn on the printer

and release when the installed memory and processor speed displays).

b. Select PRINT TESTS, and press Select (). c. Select Print Quality Pgs, and press Select ().

The message Printing Quality Test Pages is displayed.

An incorrect printer driver for the installed software can cause problems. Incorrect characters could print, and the copy may not fit the page correctly.

Measure all voltages from the connector to the printer ground.

2-48 Service Manual

Page 93

Print quality—background

Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting.

Some slick or coated papers may also cause background problems. Some problems occur with printers that run a large amount of graphics in a humid environment.

Step Questions / actions Yes No

7525-xxx

1 Read the current status of the imaging unit

from the customer menus. To view the status of the photoconductor units:

1. In Ready mode, press Menus ().

2. Select Reports, and press Select ( ).

3. Select Device Statistics, and press Select ().

It is possible a new imaging unit was installed, but the counter was not reset.

Has the imaging unit been recently replaced?

Is the background only one of the primary

colors; yellow, cyan, magenta, or black?

Did replacing the developer unit correct the

problem?

Replace the photoconductor unit.

Does this fix the problem?

Check the high-voltage contact from the HVPS

to the image transfer unit (ITU). Is a problem found?

Reset the value. To reset this value:

1. In Ready mode, press

Menus ().

2. Select Supplies Menu, and press Select ().

3. Select Replace Supply, and press Select ().

4. Select the imaging unit you want to change, and press Select ().

5. Select Yes, and press Select ().

If this does not fix the problem, go to step 2.

Replace the developer unit for the background color and retest. See “Developer unit

removal” on page 4-42.

Go to step 3.

Problem resolved. Go to step 4.

Problem resolved. Go to step 5.

Replace the failing part:

• Image transfer unit

(ITU). See “Image

transfer unit (ITU)” on page 4-35.

• High-voltage power supply (HVPS). See

“High-voltage power supply (HVPS) assembly removal” on page 4-31.

Go to step 2.

Go to step 4.

Go to step 6.

Reseat the cable in the JHVPS1 connector.

Does this fix the problem?

Replace the HVPS. See “High-voltage power

supply (HVPS) assembly removal” on page 4-31.

Does this fix the problem?

Problem resolved. Go to step 7.

Problem resolved. Go to step 8.

Diagnostic information 2-49

Page 94

7525-xxx

Step Questions / actions Yes No

Clean the printhead.

Does this fix the problem?

Problem resolved. Replace the printhead. See

“Printhead removal” on page 4-56.

Print quality—blank page

Step Questions / actions Yes No

1 Is all the packing material for the imaging unit

in question removed?

Print a document that requires all four colors

with just a few characters to verify if one specific color is a problem. For example, print the Print Quality Test Pages:

1. Enter Diagnostic mode. (Turn the printer

off, press and hold Left ( ) and Select ( ), turn the printer on, and then release the buttons when the installed memory and processor speed displays.)

2. Select PRINT TESTS, and press Select ().

3. Select Prt Qual Pgs, and press Select ().

Is only one color missing?

Go to step 2. Remove the packing

Replace the developer unit for the missing color.

material.

Go to step 3.

Replace the imaging unit. See “Imaging unit

(IU) removal” on page 4-40.

Does this fix the problem?

2-50 Service Manual

Problem resolved. Go to step 4.

Page 95

Step Questions / actions Yes No

7525-xxx

1. Remove the image unit and waste toner

bottle.

2. Replace the right cover and close the front door.

3. Enter the Diagnostics Menu (turn the printer off, press and hold and , turn the printer on, and release the buttons when installed memory and processor speed displays), and run the appropriate cartridge drive motor test for the missing color:

4. Select MISC TESTS in the Diag Menu, and press Select ().

5. Select Motor Detect. Remove Cartridge. press Select appears.

Note: Do not press Select yet.

6. Remove all toner cartridges and the imaging unit.

7. Close the front cover. If you press Select before closing the front

cover, a message appears: Close Cover. press Select.

8. press Select (). Motor Detection In Progress… appears. The

motor detection process takes about 10 seconds, and stops automatically.

Detect Complete. Rebooting… appears, and the printer performs a POR (Power On Reset).

Did the motor run?

Go to step 5. Replace the Main drive gear

assembly. See “Main drive

gear assembly with motor removal” on page 4-53.

Remove the developer unit. See “Developer

unit removal” on page 4-42. Check the

developer cartridge contacts from the HVPS to the IU.

Are all the toner cartridge contacts clean on both the Pin and IU?

Are all the spring-loaded Pin in the HVPS free

to move in and out with an equal amount of spring force?

Turn the printer off, and remove the rear shield.

See “Rear shield removal” on page 4-7. Check the continuity between the springloaded Pin and the JSC1 connector on the controller board.

Are all conductors continuous?

Replace the printhead. See “Printhead

removal” on page 4-56.

Did this fix the problem?

Go to step 6. Clean the developer

cartridge contacts. See

“Developer unit removal” on page 4-42.

Go to step 7. Replace the HVPS. See

“High-voltage power supply (HVPS) assembly removal” on page 4-31.

Go to step 8. Replace the cable.

Problem resolved. Replace the controller

board. See “Controller

board removal” on page 4-18.

Diagnostic information 2-51

Page 96

7525-xxx

Print quality—blurred or fuzzy print

Run the automatic alignment. The TPS sensor may be damaged. To run Reset Color Cal:

1. Enter the Diagnostics Menu. (Turn the printer off, press and hold and , turn

the printer on, and release the buttons when installed memory and processor speed displays.

2. Select TPS Setup from Diag Menu, and press Select ().

3. Select Reset Color Cal, and press Select ().

Resetting appears. When the reset is complete, the screen is automatically returned to TPS Setup.

Blurred or fuzzy print is usually caused by a problem in the main drive gear assembly or in the image transfer unit (ITU). Check the main drive gear assembly and ITU for correct operation.

Blurred print can also be caused by incorrect feeding from one of the input paper sources, media trays, or duplex paper path.

Check the high-voltage spring contacts to ensure they are not bent, corroded, or damaged. Replace the highvoltage power supply as necessary. See “High-voltage power supply (HVPS) assembly removal” on

page 4-31.

Print quality—half-color page

A photoconductor unit is not properly seated. Reset the specific photoconductor unit.

Print quality—horizontal banding

Print the Print Defect Page:

1. At the Ready prompt, press Menu ().

2. Select Reports, and press Select ().

3. Select Print Defects, and press Select ().

Step Questions / actions Yes No

1 Measure the distance between repeating

bands. Is the distance between bands either 34.6 or

94.2 mm?

Does the distance measure 95 mm or

108 mm?

Does the distance measure 37.7, 55, or

78.5 mm?

Replace the photoconductor unit. Remove the imaging unit and remove the original developer units, and then put them back into the new photoconductor unit, and reinstall the imaging unit. See “Imaging unit (IU)

removal” on page 4-40.

Replace the fuser. See

“Fuser assembly removal” on page 4-25.

Replace the ITU. See

“Image transfer unit (ITU)” on page 4-35.

Go to step 2.

Go to step 3.

Go to step 4.

Does the distance measure 43.9 mm or 45.5? Replace the developers that

2-52 Service Manual

match the missing color (black, cyan, magenta, or yellow). See “Developer

unit removal” on page 4-42.

Check the various rollers in the printer for debris.

Page 97

Print quality—horizontal line

Either the photoconductor unit or one of the developer units that make up the imaging unit is defective. Remove and inspect the imaging unit. Replace the damaged part of the imaging unit. See “Imaging unit (IU) removal”

on page 4-40.

Print quality—insufficient fusing

Step Questions / actions Yes No

7525-xxx

1 Is the printer setup to use the correct media? Go to step 2. Change the settings to

Check the fuser connections on the left and

right side of the printer. Are the cables and connection correct?

Is the fuser properly installed? Go to step 4. Install the fuser properly.

Replace the fuser. See “Fuser assembly

removal” on page 4-25.

Does this fix the problem?

Go to step 3. Properly reconnect or

Problem resolved. Replace the LVPS. see

indicate the correct media.

replace the cables.

“Low-voltage power supply (LVPS) assembly” on page 4-43.

Print quality—missing image at edge

Remove and reseat the following:

• Toner cartridge

• Imaging unit

• Developer units.

Print quality—mottle (2–5mm speckles)

Keep running prints through, and the problem normally clears up. If the problem persists, replace the developer cartridge.

Diagnostic information 2-53

Page 98

7525-xxx

ABCDE ABCDE

ABCDE

Print quality—narrow vertical line

Step Questions / actions Yes No

1 Replace the photoconductor unit. See

“Imaging unit (IU) removal” on page 4-40.

Problem solved. Replace the developer unit.

See “Developer unit

removal” on page 4-42

Print quality—random marks

Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor unit, developer roll, or transfer belt.

Step Questions / actions Yes No

1 Is there any loose or foreign material on the

imaging unit?

Is there any loose or foreign material on the

developer roll?

Is there any loose or foreign material on the

transfer belt?

Inspect the imaging unit by looking at the individual developers and photoconductors. Clean or replace the faulty unit. See

“Imaging unit (IU) removal” on page 4-40.

Replace the developer unit. Go to step 3.

Replace the image transfer unit. See “Image transfer

unit (ITU)” on page 4-35.

Go to step 2.

Contact your next level of support.

2-54 Service Manual

Page 99

Print quality—residual image

ABCDE ABCDE

ABCDE

Service tip: Install a new print cartridge, if available, before doing this service check. Residual image can be caused by the photoconductor, cleaning blade, and other parts inside the print cartridge.

Step Questions / actions Yes No

7525-xxx

1 Check the condition of the imaging unit using

the customer menus (administrative menus):

1. At the Ready prompt, press Menu ().

2. Select Supplies Menu, and press Select ().

3. Select Imaging Kit, and press Select ().

Does the display indicate OK?

Measure the distance from the original image

to the same point on the residual image. Is the distance 43.9 mm?

Is the distance between the original image and

the residual image 94.2 mm?

Run the Menu Setting Page twice to clear any

debris. To print a menu settings page:

1. press Menu ( ) on the operator panel.

2. Select Reports from the Admin Menu, and press Select ().

3. Select Menu Settings, and press Select ().

Is there still any toner contamination on the fuser assembly?

Go to step 2. Replace the imaging unit or

Replace the developer corresponding to the color of the image. See “Developer

unit removal” on page 4-42.

Replace the photoconductor. See

“Developer unit removal” on page 4-42.

Replace the fuser. See

“Fuser assembly removal” on page 4-25.

the photoconductor unit. See “Imaging unit (IU)

removal” on page 4-40.

Replace the imaging unit or the photoconductor unit. See “Imaging unit (IU)

removal” on page 4-40.

Contact your next level of support.

Diagnostic information 2-55

Page 100

7525-xxx

Print quality—solid color page

Service tip: A solid color page is generally caused by a problem in the high-voltage controller or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum.

Step Questions / actions Yes No

1 Replace the photoconductor unit (part of the

imaging unit). Remove the imaging unit and remove the developers. Place the original developers in the new photoconductor, and then replace the imaging unit. See “Imaging

unit (IU) removal” on page 4-40.

Does this fix the problem?

A faulty printhead can cause the problem. To

test the printhead for solid colors, place a narrow strip of paper over the gap between the developers. Make sure the paper stays in place when you replace the imaging unit. This will block the laser from discharging the photoconductors. Print a Quality Test Page.

Does the page have a white vertical band?

Check the high-voltage contact from the HVPS

to the photoconductor charge roll. Ensure the contact springs are properly mounted and that the charge roll contact spring is making good contact with the HPVS spring that runs through the left printer frame. See “Toner cartridge

contacts” on page 4-59 to view the proper

mounting and for removal procedures. Are the spring(s) defective?

Turn the printer off, and check the continuity of

the HVPS cable. Is there continuity?

Problem resolved. Go to step 2.

Replace the printhead. See

“Printhead removal” on page 4-56.

Replace the transfer contact assembly. See “Toner

cartridge contacts” on page 4-59.

Go to step 5. Replace the cable assembly.

Go to step 3.

Go to step 4.

Replace the HVPS. See “High-voltage power

supply (HVPS) assembly removal” on page 4-31.

Did this solve the problem?

Print quality—vertical banding

Replace the developer cartridge.

2-56 Service Manual

Problem resolved. Replace the controller

board. See “Controller

board removal” on page 4-18.

Lexmark X543, X544, X546 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 Seguridad

Informações de Segurança

Informació de Seguretat

Preface

1. General information

Models

Options and features

Memory

Print quality

Connectivity (network support)

Operating modes

Data streams

Dimensions

Clearances

Power and electrical specifications

Acoustics

Environment specifications

Media handling

Input and output sources

Duplex capability

Media input size specifications

Media input type specifications

Media output size and type

Media guidelines

Digital imaging specifications

General specifications

Scan and copy specific specifications

Fax specifications

Tools required for service

Acronyms.

2. Diagnostic information

Start

POR (Power-On Reset) sequence

Symptom tables

Printer symptom table

Scan / fax / copy symptom table

Print quality symptom table

Error codes and messages

User status and attendance messages

Paper Jam messages

Service error messages

Fax error log codes

Service checks

90x.xx error

925.01—Fan error service check

Printhead service check

950.xx NVRAM failure service check

Autocompensator mechanism service check

Bin full sensor service check

Dead printer service check

Duplex/manual feed sensor (S1) service check

Front door sensor or switches service check

Fuser exit sensor service check

Fuser service check

Input sensor (S2) service check

Main drive gear assembly (EP drive) service check

Operator panel service check

Op panel USB cable service check