Toshiba e-STUDIO500P Service Manual Download

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1-10

S ervice Manual

O ther

E nvelope1

98.4 x 162 mm

to 176 x 250 mm

(3.87 x 6.38 in.

to 6.93 x 9.84 in.)

98.4 x 162 mm X X X

to 229 x 342 mm

(3.87 x 6.38 in.

to 9.01x 12.76 in.)

T his size does not appear in the P aper S ize menu until Tray S ize S ens ing is turned off.

T his size s etting formats the page for 215.9 x 355.6 mm (8.5 x 14 in.) unles s the size is specified by the software

application.

No univers al s upport for the following options: 2000-s heet drawer, E nvelope Feeder, 5-bin mailbox.

3.5 in. s etting not s upported if other options are ins talled above the 250 univers ally adjus table tray.

P rint media types

P rint media

-s

(

)

-s

P aper X X X X X

C ard s tock X X

X X

Transparencies X X

P aper labels

X X

P rinting label applications on the printer requires a s pecial label fuser cleaner which prevents duplexing. T he label fus er

cleaner is included with a s pecial label cartridge for label applications.

P rint media s izes (c ontinued)

P rint media
s ize
(

indicates

s upport)

Dimens ions
(UAT — univers ally
adjus table tray)

-s

)

-s

(

)

(

)

X X X

Summary of Contents for e-STUDIO500P

Page 1: ...PRINTER P N 12G9609 e STUDIO500P ...

Page 2: ...ns Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Toshiba America Business Solutions 2 Musick Irvine CA 92618 Attn Service Training Toshiba may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can download copies of this manual from the Toshiba F...

Page 3: ... 7 Acoustics 1 7 Media specifications 1 8 Paper and specialty media guidelines 1 8 Supported print media 1 8 Selecting print media 1 15 Paper 1 15 Paper characteristics 1 15 Weight 1 15 Unacceptable paper 1 15 Transparencies 1 16 Selecting transparencies 1 16 Envelopes 1 16 Labels 1 17 Card stock 1 18 Storing print media 1 18 Avoiding jams 1 19 Print area 1 19 Tools required 1 19 Acronyms 1 20 Dia...

Page 4: ...ck 2 82 Envelope feeder service check 2 84 Fuser service checks 2 87 920 xx Cold fuser service check 2 87 922 xx Cold fuser check 2 89 923 xx Hot fuser service check 2 90 924 xx Hot fuser service check 2 91 925 xx Hot fuser service check 2 91 Fuser exit sensor service check 2 92 Fuser narrow media sensor service check 2 93 Fuser solenoid service check 2 94 High capacity feeder input tray service c...

Page 5: ...ick Test duplex 3 9 Top Margin duplex 3 10 Sensor Test duplex 3 10 Motor Test duplex 3 11 Duplex Feed 1 3 12 Duplex Feed 2 3 12 INPUT TRAY TESTS 3 13 Feed Tests input tray 3 13 Sensor Test input tray 3 13 OUTPUT BIN TESTS 3 14 Feed Tests output bins 3 14 Feed To All Bins 3 14 The test is continuous until Stop is pressed 3 14 Sensor Test standard output bin 3 15 Sensor Test Output Expander 3 15 Sen...

Page 6: ... Pgs 3 26 SIZE SENSING 3 27 Panel Menus 3 27 PPDS Emulation 3 27 Download Emuls 3 27 Demo Mode 3 27 Factory Defaults 3 28 Energy Conserve 3 28 EVENT LOG 3 28 Paper Prompts 3 28 Env Prompts 3 28 Jobs On Disk 3 28 Disk Encryption 3 28 Font Sharpening 3 29 LCD Brightness 3 29 LCD Contrast 3 29 Exit Config Menu 3 29 Additional useful menu locations 3 29 Hex Trace 3 29 Menu settings page 3 30 Printing ...

Page 7: ...ight frame extensions 4 17 Pass thru plate 4 18 Laser cover removal 4 19 Bevel gear removal 4 21 Cartridge duct removal 4 23 Developer drive assembly removal 4 24 Developer drive coupler kit removal 4 25 ESD cover removal 4 25 Fuser assembly removal 4 26 Fuser exit sensor removal 4 28 Fuser exit sensor flag and spring removal 4 30 Fuser lamp removal 4 32 Fuser narrow media sensor removal 4 34 Fuse...

Page 8: ...tacker board 5 8 High voltage power supply 5 9 Interconnect card 5 9 Low voltage power supply 5 10 Output expander control board 5 11 StapleSmart finisher 5 12 Preventive maintenance 6 1 Safety inspection guide 6 1 Lubrication specifications 6 1 Scheduled maintenance 6 1 Maintenance kit 6 1 Parts catalog 7 1 How to use this parts catalog 7 1 Assembly 1 Covers 7 2 Assembly 2 Frame 1 7 4 Assembly 3 ...

Page 9: ... 48 Assembly 29 Output expander 2 7 49 Assembly 30 High capacity output expander 1 7 50 Assembly 31 High capacity output expander 2 7 51 Assembly 32 High capacity output expander 3 7 52 Assembly 33 5 bin mailbox 1 7 54 Assembly 34 5 bin mailbox 2 7 56 Assembly 35 High capacity feeder 1 7 58 Assembly 36 High capacity feeder 2 7 60 Assembly 37 High capacity feeder 4 7 62 Assembly 38 High capacity fe...

Page 10: ...x Service Manual ...

Page 11: ...odukte 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 Laserbestr...

Page 12: ... 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...

Page 13: ...orpen 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 lase...

Page 14: ...ts 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 S...

Page 15: ...Laser notices xv Japanese Laser Notice ...

Page 16: ...xvi Service Manual Korean Laser Notice ...

Page 17: ...e product before you begin or use caution if the product must receive power in order to perform the task Consignes de sécurité La sécurité de ce produit repose sur des tests et des agréations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilité concernant la sécurité en cas d utilisation de pièces de rechange non agréées Les consignes d...

Page 18: ...l 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 ...

Page 19: ...cte 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 p...

Page 20: ...n 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 Definitions Note A note...

Page 21: ...omplete the repair perform tests as needed to verify the repair S ee S tart on page 2 1 Options The following options are available S ome options are not available in every country C ontact your point of purchase for options available in your country Memory options of 128MB and 512 S DR AM Media handling operations 2000 sheet high capacity feeder E nvelope feeder Duplex Option Model name C onfigur...

Page 22: ...1 2 S ervice Manual Configured model The following illustration shows a standard network printer ...

Page 23: ...0 600 dpi Simplex printing from Ready on full size media seconds Letter 8 5 in x 11 in 11 7 6 0 12 1 8 5 12 1 8 5 A4 8 3 in x 11 7 in 17 0 11 4 22 7 13 0 22 7 13 0 Legal 8 5 in x 14 in 14 5 12 1 24 3 24 3 24 3 13 5 Simplex printing from Power Saver on full size media seconds Simplex Letter 25 3 28 2 28 2 The test job consists of the character A followed by a form feed single page job The first cop...

Page 24: ...lable from Toshiba Operating clearances Memory type S tandard DR AM MB 128 Optional memory MB 100 pin DDR S DR AM unbuffered DIMMs 128 and 512MB available Maximum MB 640 Printer s ide Meas urement Left and right side 12 in 30 48 cm Front 20 in 50 8 cm R ear 12 in 30 48 cm Top 54 in 137 16 cm Allow clearance above the printer front door clearance and for adding options such as additional input draw...

Page 25: ...ion 2 13 in 15 6 in 23 4 in 11 lb 500 Sheet drawer 5 3 in 134 mm 15 6 in 398 mm 20 5 in 520 mm 7 lb 3 2 kg 2 000 Sheet 11 8 in 300 mm 15 6 in 398 mm 19 5 in 495 mm 31 lb 14 1 kg Envelope option closed position 7 72 in 196 mm 4 lb 1 8 kg Envelope option support fully extended 12 28 in 312 mm 4 lb 1 8 kg Envelope option fits within height and width of printer e STUDIO 500P ...

Page 26: ...0 to 60 Hz nominal not available in all countries 190 to 259 V ac extreme Notes Using a 220 to 110 power converter with the 110 volt printer is not recommended All models are ENERGY STAR qualified The default timeout to power saver is 30 minutes for all models Printing states Off all models 05 W 05 W 05 W Idle average power Power Saver on 20 W 20 W 20 W Power Saver off 90 W 95 W 95 W Continuous pr...

Page 27: ... Storage environment unpacked Temperature 0 to 40 C 32 to 104 F Relative humidity 5 to 80 Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296 Model Status 1 Meter average sound pressure Declared sound power Simplex printing 53 dBA 6 7 Bels Duplex printing 55 dBA N M Bels Idle standby mode 32 dBA 4 7 Bels Simplex printing 54 dBA 6 8 Bels Duplex printing 57 dBA ...

Page 28: ...rays and bins Print media sizes Print media weights Media weights supp or ted in opt ional output bins Media sizes suppo rted in the finisher Media weights supp or ted in the finisher Note If you u s e a print media size not lis ted select the next larger size Print media s izes Print media s ize indicates s uppor t Dimens ions UAT univers ally adjus table tray 250 s heet tray 500 s heet tray 250 ...

Page 29: ...3 875 x 7 5 in 9 E nvelope 98 4 x 225 4 mm 3 875 x 8 9 in 10 E nvelope 104 8 x 241 3 mm 4 12 x 9 5 in DL E nvelope 110 x 220 mm 4 33 x 8 66 in C 5 E nvelope 162 x 229 mm 6 38 x 9 01 in B5 E nvelope 176 x 250 mm 6 93 x 9 84 in Print media s izes continued Print media s ize indicates s uppor t Dimens ions UAT univers ally adjus table tray 250 sheet tray 500 sheet tray 250 sheet drawer option 250 UAT...

Page 30: ...ns are installed above the 250 universally adjustable tray Print media types Print media 500 s heet drawer option Multipurpos e feeder 2000 s heet drawer E nvelope feeder Duplex unit S tandard output bin Paper X X X X X C ard stock X X X X Transparencies X X X Paper labels1 X X 1 Printing label applications on the printer requires a special label fuser cleaner which prevents duplexing The label fu...

Page 31: ...bond Labels maximum2 Paper 180 g m2 48 lb bond 163 g m2 43 lb bond Dual web paper 180 g m2 48 lb bond 163 g m2 43 lb bond Polyester 220 g m2 59 lb bond 220 g m2 59 lb bond Vinyl5 300 g m2 92 lb liner 260 g m2 78 lb liner Integrated forms Pressure sensitive area must enter the printer first 140 to 135 g m2 140 to 135 g m2 Paper base grain long 75 to 135 g m2 20 to 36 lb bond 75 to 135 g m2 20 to 36...

Page 32: ...formance use 75 g m2 20 lb bond grain long paper When using paper narrower than 182 x 257 mm 7 2 x 10 1 in make sure the weight is greater than or equal to 90 g m2 24 lb bond Unacceptable paper The following papers are not recommended for use with the printer Chemically treated papers used to make copies without carbon paper also known as carbonless papers carbonless copy paper CCP or no carbon re...

Page 33: ...o optimize feed reliability After printing approximately 10 000 pages of labels or each time you replace the print cartridge complete the following steps to maintain printer feeding reliability 1 Print five sheets of paper 2 Wait approximately five seconds 3 Print five more sheets of paper When printing on labels Set the Paper Size Type menu item to Labels in the Paper Menu You can set the Paper S...

Page 34: ...rom the operator panel from the printer driver in the Local Printer Setup Utility or from MarkVision Be aware that preprinting perforation and creasing can significantly affect the print quality and cause print media handling or jamming problems Avoid using card stock that may release hazardous emissions when heated Do not use preprinted card stock manufactured with chemicals that may contaminate ...

Page 35: ... Do not use print media that you have cut or trimmed yourself Do not mix print media sizes weights or types in the same print media source Make sure the recommended print side is loaded in the source according to your simplex or duplex needs Keep print media stored in an acceptable environment See Storing print media on page 1 18 Do not remove trays during a print job Push all trays in firmly afte...

Page 36: ... Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply MPF Multipurpose feeder MROM Masked Read Only Memory MS Microswitch NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer OPT Optical Sensor PC Photoconductor pel Picture element POR Power On Reset POST Power On Self Test PP Parts Packet PWM Puls...

Page 37: ...age 2 6 StapleSmart finisher on page 2 7 Service errors 9xx xx s If a service error code appears while you are working on the machine go to Service error codes on page 2 8 and take the indicated action for that error Service error codes are indicated by a three digit error code followed by a period and additional numbers in the format XXX YY In most cases five digits are shown User status and atte...

Page 38: ...inter is not ready Stop Press Stop to stop the mechanical operation of the printer After pressing Stop the message Stopping is displayed When the printer has stopped the status line in the operator panel will show Stopped and a list of options will appear Navigation buttons The Up or Down buttons are used to move up and down lists When navigating through a list using the Up or Down button the curs...

Page 39: ...It will also display the current status and the Supplies Warnings status If multiple warnings are present each warning will be separated by a comma The other three lines of the display are the body of the screen This is where you view printer status supplies messages show me screens and make selections Operator panel continued Button Function Paper Menu Default Source Paper Size Type Configure MP ...

Page 40: ...on For example 8 The fuser lamp turns on The fuser takes longer to warm up from a cold start than a warm start 9 The operator panel LED starts blinking 10 A clock face appears on the display If present the following errors or messages may display 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 Cartridg...

Page 41: ... Print quality black page Go to Print quality all black page on page 2 116 Print quality blank page Go to Print quality blank page on page 2 117 Print quality light print Go to Print quality light print on page 2 121 Print quality background Go to Print quality background on page 2 118 Print quality residual image Go to Print quality residual image on page 2 120 Print quality skew Go to Paper feed...

Page 42: ...ymptoms Symptom Action Paper feed problem with Duplex Go to Duplex option service check on page 2 82 Paper jams at Paper Removal Tray Go to Duplex option service check on page 2 82 Paper skews in the Duplex Option Go to Duplex option service check on page 2 82 Paper fails to pass from lower option through the Duplex Option Go to Duplex option service check on page 2 82 Envelope feeder symptoms Sym...

Page 43: ...Diagnostic information 2 7 ...

Page 44: ...System board and inner shield removal on page 4 76 905 xx Interface violation by Paperport device These errors indicate an unrecoverable system software error Replace the system board See System board and inner shield removal on page 4 76 906 xx RIP interface driver error These errors indicate an unrecoverable system software error Replace the system board See System board and inner shield removal...

Page 45: ... 999 Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Incorrect hot roll Go to 920 xx Cold fuser service check on page 2 87 920 06 Fuser is not increasing in temperature even though the lamp has been on for an extended time Fuser page count between 0 and 99 999 Fuser is not receiving AC power Poor supply line voltage G...

Page 46: ...l Go to 920 xx Cold fuser service check on page 2 87 920 16 Fuser is not increasing in temperature even though the lamp has been on for an extended time Fuser page count between 100 000 and 199 999 Fuser is not receiving AC power Poor supply line voltage Go to 920 xx Cold fuser service check on page 2 87 920 17 Fuser has been below the desired temperature for too long while the media is in the nip...

Page 47: ...amp Incorrect hot roll Go to 920 xx Cold fuser service check on page 2 87 920 26 Fuser is not increasing in temperature even though the lamp has been on for an extended tim Fuser page count between 200 000 and 299 999 Fuser is not receiving AC power Poor supply line voltage Go to 920 xx Cold fuser service check on page 2 87 920 27 Fuser has been below the desired temperature for too long while med...

Page 48: ... Go to 920 xx Cold fuser service check on page 2 87 920 36 Fuser is not increasing in temperature even though the lamp has been on for an extended time Fuser page count between 300 000 and 399 999 Fuser is not receiving AC power Poor supply line voltage Go to 920 xx Cold fuser service check on page 2 87 920 37 Fuser has been below the desired temperature for too long while media is in the nip Fuse...

Page 49: ...ct hot roll Go to 920 xx Cold fuser service check on page 2 87 920 46 Fuser is not increasing in temperature even though the lamp has been on for an extended time Fuser page count between 400 000 and 499 999 Fuser is not receiving AC power Poor supply line voltage Go to 920 xx Cold fuser service check on page 2 87 920 47 Fuser has been below the desired temperature for too long while media is in t...

Page 50: ...roll Go to 920 xx Cold fuser service check on page 2 87 920 56 Fuser is not increasing in temperature even though the lamp has been on for an extended time Fuser count more than 500 000 Fuser is not receiving AC power Poor supply line voltage Go to 920 xx Cold fuser service check on page 2 87 920 57 Fuser has been below the desired temperature for too long while media is in the nip Fuser page coun...

Page 51: ...on the fuser Low voltage or incorrect lamp Incorrect hot roll Go to 920 xx Cold fuser service check on page 2 87 920 96 Fuser is not increasing in temperature even though the lamp has been on for an extended time Fuser page count not available Fuser is not receiving AC power Poor supply line voltage Go to 920 xx Cold fuser service check on page 2 87 920 97 Fuser has been below the desired temperat...

Page 52: ...r not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 89 922 12 Hot roll took too long to reach the beginning lamp detection temperature Fuser page count between 100 000 and 199 999 Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 89...

Page 53: ... circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 89 922 24 Hot roll timed out in trying to reach the final lamp detection temperature Fuser page count between 200 000 and 299 999 Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Col...

Page 54: ...k on page 2 89 922 36 Hot roll did not reach operating temperature in time new enhanced control Fuser page count between 300 000 and 399 999 Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 89 922 37 Fuser has taken too long to reach desired temperature after increasing interpage...

Page 55: ...pply line voltage Go to 922 xx Cold fuser check on page 2 89 922 52 Hot roll took too long to reach the beginning lamp detection temperature Fuser page count stopped at 500 000 to preserve data Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 89 922 53 Hot roll reached final lamp...

Page 56: ... lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 89 922 94 Hot roll timed out in trying to reach the final lamp detection temperature Fuser page count not available Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 ...

Page 57: ... at 500 000 to preserve data Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults Go to 923 xx Hot fuser service check on page 2 90 923 91 Fuser over temperature Fuser page count not available Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults Go to 923 xx Hot fuser service check on pa...

Page 58: ... POR machine after receiving a 925 01 Go to 925 xx Hot fuser service check on page 2 91 925 11 Lamp detection performed and found error Fuser page count between 100 000 and 199 999 115 V lamp in 220 V printer Lamp has excessive wattage Go to 925 xx Hot fuser service check on page 2 91 925 12 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count between ...

Page 59: ...25 52 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count stopped at 500 000 to preserve data Attempting to POR machine after receiving a 925 01 Go to 925 xx Hot fuser service check on page 2 91 925 91 Lamp detection performed and found error Writes to the fuser information chip have been disabled due to a previous write failure 115 V lamp in 220 V pr...

Page 60: ...al Go to Main fan on page 2 76 929 00 Toner sensor error a problem has been detected with the toner sensor Check the toner sensor Check cable Check system board Go to Toner sensor service check on page 2 127 929 66 An error has been detected No home windows has been detected Check toner cartridge Check toner sensor Go to Toner sensor service check on page 2 127 929 67 No toner sensor transition Ch...

Page 61: ...inds Defective motor Check motor cable and connections Go to Main drive service check on page 2 105 936 31 No lock detected at motor start for motor ID Motor is type 1 Check for paper jams Gear binds Defective motor Check motor cable and connections Go to Main drive service check on page 2 105 936 60 No lock detected at normal motor start Motor is type 0 Check for paper jams Gear binds Defective m...

Page 62: ...re detection Motor is type 0 Excessive gear loading in gearbox assembly Go to Main drive service check on page 2 105 939 00 RIP engine communications lost System board POR the printer several times if the error code continues to be displayed replace the system board See System board and inner shield removal on page 4 76 940 00 LVPS zero crossing test failed Incorrect LVPS installed Noisy AC power ...

Page 63: ...ly replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed ab...

Page 64: ...perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has bee...

Page 65: ...ubleshooting components Once a component has been installed in a printer it can not be used in another printer It must be returned to the manufacturer 955 00 Code CRC CRC failure or ECC code failure on the system board Replace the system board See System board and inner shield removal on page 4 76 956 00 System board This error indicates a system board processor failure Replace the system board Se...

Page 66: ...ived by device Invalid command received by the specified device 984 00 Invalid command parameter received by device Invalid command parameter received by the specified device 990 00 General device equipment check Indicates an equipment check condition has occurred in the specified device but the device is unable to identify the exact component failure Service errors 980 thru 984 device can be one ...

Page 67: ... through 5 is missing If multiple trays are missing they are prioritized in this order Tray 1 2 then Tray 5 Tray x Missing status clears whenever Tray x is reinserted If the Tray 1 Missing message does not clear when tray 1 is inserted go to Parallel port service check on page 2 116 If Tray 2 through 5 Missing message does not clear by inserting the tray go to Input tray s service check on page 2 ...

Page 68: ...urce custom string This message displays when the user should change the media installed in one of the input options input source Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 MPF Feeder Envelope Feeder custom string a user definable name Change input source size This message displays when the user should change the media installed in one of the input options input source Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 M...

Page 69: ...d to the printer but a communications problem may prevent the printer from detecting the option For example there may be a poor connection or a hardware failure The following actions may be taken If the option was temporarily removed or not connected properly reattach or reconnect it Press to execute a configuration change which notifies the printer the option has been hot unplugged removed with t...

Page 70: ...sher side door has been closed Before the first page of a job requesting hole punch The message displays once per job The following actions can be taken Install the hole punch box Press to ignore the message The Box M Missing message appears on the status line A job that is set for hole punching will not be punched The message continues to display on all subsequent jobs that request hole punching ...

Page 71: ...dling option has been hot unplugged The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed The following actions may be taken Install the option Press until Busy Waiting displays Select one of the following Cancel Job Reset Printer Reset Active Bin If the message cannot be cleared go to Input tray s service ch...

Page 72: ...ice check on page 2 102 Load Staples This message displays when the Staples Empty Alarm is activated and one of the following occurs There are no staples in the stapler The maximum number of staples have been fired after the engine has reported that the staple cartridge is low The printer does not detect the staple cartridge is present The following actions may be taken Install a new staple cartri...

Page 73: ...ilure The following actions may be taken If the option was temporarily removed or not connected properly reattach or reconnect it Press to execute a configuration change which notifies the printer the option has been hot unplugged removed with the power on Note This action is not available if the printer is in Diagnostics Mode or running diagnostics If the device is experiencing a hardware problem...

Page 74: ...ton assembly service check on page 2 122 34 xx Short Paper The printer determines the paper length is too short to print the formatted data This occurs when the printer does not know the actual paper size loaded in the tray For auto size sensing trays this error occurs if the paper stop is in the incorrect position Make sure the Paper Size setting is correct for the size paper that is being used 3...

Page 75: ... Cancel Job Reset Printer Reset Active Bin 39 xx Complex Page This message displays when the page is too complex to print The following actions may be taken Press to clear the message and continue the job Some data loss may occur Simplify the print job and reprint if necessary Press until Busy Waiting appears The following selections are possible Cancel Job Reset Printer Reset Active Bin 50 xx PPD...

Page 76: ...s the standard serial port but the port has been disabled 56 xx Serial Port x Disabled This error displays when data is sent to the printer across an optional parallel port but the port has been disabled Once this message displays reporting of further errors is suppressed until the menus are entered or the printer is reset 56 xx Standard USB Port Disabled Displayed when status is requested over th...

Page 77: ...he disk because the configuration of the printer has changed This message alternates with the secondary message Held jobs may not be restored Some configuration changes that may cause this condition are Code version change Paper handling option is removed Disk has been moved to a different model printer Press to clear the message Some of the Print and Hold jobs stored on the disk will not be resto...

Page 78: ...tects an unformatted disk at power on Press to clear the message The disk is marked as bad and normal operation continues Disk operations are not allowed until the disk is formatted 64 xx Unsupported Disk Format The printer detects an unsupported disk format at POR Press to clear the message The disk is marked as bad and normal operation continues Further disk operations are not allowed until the ...

Page 79: ...e Explanation Parallel Standard Parallel Port if available Serial Standard Serial Port if available Serial x Serial Port is attached to PCI connector x where x 1 2 or 3 Network x Network card x is attached to PCI connector x where x 1 2 or 3 LocalTalk x LocalTalk Card x is attached to PCI connector x where x 1 2 or 3 Infrared Standard Infrared port if available Infrared x Infrared Port x is attach...

Page 80: ...Check for anything in the paper path that might cause the paper to jam If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 102 200 02 Input sensor covered too long Multi sheet feed that is shingled Tray size sensing wrong size Paper jam leaving page over sensor Fan media and stack flat in tray or MPF Check for anything in the paper path that might cause the ...

Page 81: ...rive motor error possibly due to mechanical load Main drive motor not working Go to Main drive service check on page 2 105 200 32 Detected cover switch bounce Upper cover not fully closed Cover switch not functioning correctly Go to Cover closed switch cable service check on page 2 80 201 00 Page did not reach exit sensor Fuser page count between 0 and 99 999 Page jammed on fuser input guide Page ...

Page 82: ...y removal on page 4 26 If media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be operating properly Go to Fuser narrow media sensor service check on page 2 93 201 10 Page did not reach exit sensor Fuser page count between 100 000 and 199 999 Page jammed on fuser input guide Page...

Page 83: ...user assembly removal on page 4 26 If media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be operating properly Go to Fuser narrow media sensor service check on page 2 93 201 20 Page did not reach exit sensor Fuser page count between 200 000 and 299 999 Page jammed on fuser inpu...

Page 84: ...ly removal on page 4 26 If media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 93 201 30 Page did not reach exit sensor Fuser page count between 300 000 and 399 999 Page jammed on fuser input guide P...

Page 85: ...user assembly removal on page 4 26 If media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 93 201 40 Page did not reach exit sensor Fuser page count between 400 000 and 499 999 Page jammed on fuser in...

Page 86: ... removal on page 4 26 If media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 93 201 50 Page did not reach exit sensor Fuser page count stopped at 500 000 to preserve data Page jammed on fuser input g...

Page 87: ...user assembly See Fuser assembly removal on page 4 26 If media is narrow then turn off first sheet detection engine settings 3 16 In Diagnostics mode select PRINTER SETUP and Engine Setting 3 The fuser narrow media sensor may not be functioning properly Go to Fuser narrow media sensor service check on page 2 93 201 90 Page did not reach exit sensor Fuser page count is not available Page jammed on ...

Page 88: ...accordion jam Fuser page count is not available Page did not enter or exit fuser nip cleanly Narrow media sensor not functioning correctly Actual page is narrow when wide page was expected If label media ensure front edge meets 1 8 inch requirement Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 26 If media is narrow t...

Page 89: ...to Fuser exit sensor service check on page 2 92 202 01 Page did not cleanly exit fuser or redrive area Fuser page count between 0 and 99 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce...

Page 90: ...03 Page is covering narrow media sensor during warm up Fuser page count between 0 and 99 999 If page is not visible from front or rear of machine partial piece of page may be torn off in fuser covering narrow media sensor Narrow media sensor or flag may be dislodged damaged Check the fuser for any signs of a piece of media stuck in the fuser 202 04 Exit sensor bounced Fuser page count between 0 an...

Page 91: ...to Fuser exit sensor service check on page 2 92 202 11 Page did not cleanly exit fuser or redrive area Fuser page count between 100 000 and 199 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to...

Page 92: ...dia sensor during warm up Fuser page count between 100 000 and 199 999 If page is not visible from front or rear of the machine partial piece may be torn off in the fuser covering the narrow media sensor The narrow media sensor or flag may be dislodged or damaged Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 202 14 Exit sensor bounced Fuser ...

Page 93: ...Go to Fuser exit sensor service check on page 2 92 202 21 Page did not cleanly exit fuser or redrive area Fuser page count between 200 000 and 299 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over...

Page 94: ...ensor during warm up Fuser page count between 200 000 and 299 999 If page is not visible from front or rear of the printer a partial piece of page may be torn off in the fuser covering the narrow media sensor The narrow media sensor or flag may be dislodged or damaged Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 202 24 Exit sensor may have ...

Page 95: ...y Go to Fuser exit sensor service check on page 2 92 202 31 Page did not cleanly exit fuser or redrive area Fuser page count between 300 000 and 399 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media ov...

Page 96: ...sensor during warm up Fuser page count between 300 000 and 399 999 If page is not visible from front or rear of the printer a partial piece of a page may be torn off in the fuser covering the narrow media sensor The narrow media sensor or flag may be dislodged or damaged Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 202 34 Exit sensor may ha...

Page 97: ...o to Fuser exit sensor service check on page 2 92 202 41 Page did not cleanly exit fuser or redrive area Fuser page count between 400 000 and 499 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over ...

Page 98: ...ring warm up Fuser page count between 400 000 and 499 999 If page is not visible from front or rear of the printer a partial piece of a page may be torn off in the fuser covering the narrow media sensor The narrow media sensor or flag may be dislodged or damaged Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 202 44 Exit sensor may have bounce...

Page 99: ...rly Go to Fuser exit sensor service check on page 2 92 202 51 Page did not cleanly exit fuser or redrive area Fuser page count stopped at 500 000 to preserve data Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Tur...

Page 100: ...m up Fuser page count stopped at 500 000 to preserve data If page is not visible from front or rear of the printer a partial piece of a page may be torn off in the fuser covering the narrow media sensor The narrow media sensor or flag may be dislodged or damaged Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 202 54 Exit sensor may have bounce...

Page 101: ...to Fuser exit sensor service check on page 2 92 202 91 Page did not cleanly exit fuser or redrive area Fuser page count is not available Page may be jammed in the fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 26 Turn media over to reduce...

Page 102: ... media sensor during warm up Fuser count is not available If page is not visible from front or rear of the printer a partial piece of a page may be torn off in the fuser covering the narrow media sensor The narrow media sensor or flag may be dislodged or damaged Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media 202 94 Exit sensor may have bounce...

Page 103: ... Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check duplex unit for correct installation and alignment to the printer If available try another duplex option If none is available go to 232 xx Jam displays on the operator panel on page 2 83 233 00 Paper failed to make duplex doublefeed sensor during turnaroun...

Page 104: ...ion if available If another one is not available replace the duplex option 237 00 Paper did not reach the printer input sensor from the duplex unit Duplex jam access tray is not fully latched Printer PTO not driving the duplex feed folls Duplex feed system not working correctly Make sure the duplex jam access tray is installed correctly Make sure the power takeoff shaft and spring are correctly in...

Page 105: ... having mechanical or electrical problems Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available If one is not available replace the duplex option 238 04 Duplex doublefeed sensor covered Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems Remove any sheets from the duplex option Try the d...

Page 106: ...ed system Replace the duplex option 239 05 Duplex did not send Page In Output Device response Mechanical feed error due to belt slipping Timing error due to feed system Replace the duplex option 239 06 Failed the last page of a staple job Mechanical feed error due to belt slipping Timing error due to feed system Replace the duplex option 239 07 Engine never sent Select OUtput Device to the duplex ...

Page 107: ...taminated pick tires Overfilling of tray past the fill line Fan media Turn media over Reduce amount of media loaded in tray 1 Replace pick tires Integrated tray autocompensator pick roll assembly removal on page 4 51 241 12 Page was not properly picked from tray 1 Failure to feed possible causes include Edge locking Worn or contaminated pick tires Overfilling of tray past the fill line Fan media T...

Page 108: ...options as installed Service tip If more than a single output option is installed check each one to see if the printer recognizes any single option as being installed If the printer recognizes any of the output options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized option Continue with this service check or go to the service check for the fai...

Page 109: ...y If correct check to make sure the top pass thru sensor is correctly connected to J11 on the control board Disconnect the pass thru sensor cable and check the voltage at J11 3 The voltage measures approximately 5 V dc If incorrect check the voltage at J11 2 The voltage measures approximately 0 V dc If incorrect replace the sensor assembly If this does not fix the problem replace the lower control...

Page 110: ...mbly If correct replace the control board 3 Mechanical linkage Motor assembly If the DC motor is functioning properly check the gears clutch and other linkage parts for correct operation and wear broken gear teeth or damaged parts If incorrect replace the mechanical linkage assembly DC motor assembly FRU Action 1 Mechanical linkage DC motor assembly Check the DC motor cable connector to be sure it...

Page 111: ...Error Code 900 continues to display go to step 3 3 Factory defaults Restore factory defaults See Factory Defaults on page 3 28 This resets the non critical areas of the user NVRAM If Error Code 900 continues to display go to step 4 4 Sub error codes With Error Code 900 displayed press and Record the complete list of Sub Error Codes on the display Check the Base printer sub error codes on page 2 9 ...

Page 112: ... POR then stop Fan will not run when trying to print Main fan System board Measure the voltage at J4 1 on the system board The voltage should measure approximately 2 5 V dc If incorrect replace the main fan See Main fan removal on page 4 56 If that does not fix the problem replace the system board See System board and inner shield removal on page 4 76 4 Main fan blades do not turn Measure the volt...

Page 113: ...erconnect card FRU Action 1 Interconnect card If the interconnect card been recently replaced go to step 3 If the card has not been replaced go to step 2 2 operator panel board If the operator panel board has been recently replaced go to step 4 If the operator panel board has not been replaced contact your next level of support 3 Interconnect card Replace the current interconnect card assembly wit...

Page 114: ... installed in the printer The system board has a label with an board ID and barcode Use the first eight numbers to identify the board with the part number in the table below This error code indicates a mismatch between the system board and the interconnect card Model Board bar code Corresponds to P N 4061 000 non network Q0016021 40X0140 4061 010 network Q0016001 40X0141 4061 200 non network Q0016...

Page 115: ...m remains contact the next level of support 6 System board Replace the original system board with a new and not previously installed system board If the problem remains contact the next level of support FRU Action 1 Charge roll assembly Check the charge roll for correct installation toner buildup marks cuts or other signs of contamination or damage Replace as necessary 2 Left side charge roll link...

Page 116: ...t loose or broken Make sure the cover closed switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover closed switch spring 2 Cover closed switch cable assembly Check the cover closed switch for proper mechanical operation If incorrect repair as necessary Disconnect the cover closed switch cable from J8 at the system board and measure the voltage at ...

Page 117: ... 6 If the voltage is incorrect replace the LVPS assembly See Low voltage power supply removal on page 4 54 6 Features or option installed on the interconnect card assembly Warning Observe all the ESD precautions and turn the printer off before any feature or option cards are removed or replaced Remove one option feature at a time to help isolate the failing part Replace the faulty part 7 LVPS fuse...

Page 118: ...cks verify the media used in the duplex option meets specification and is not dog eared or damaged in any way See Media specifications on page 1 8 23x xx jam code Jam location 231 xx Media did not arrive at the duplex input sensor but did leave the fuser exit sensor 232 xx Media did not clear the duplex input sensor but did leave the printer fuser exit sensor 233 xx Media failed to make the duplex...

Page 119: ...ect check for any paper or other objects that might cause a paper jam If none are found replace the duplex option assembly FRU Action 1 Duplex input sensor If the paper reaches the duplex input sensor but does not clear the sensor make sure the sensor is connected to the duplex system board If connected correctly check for correct operation of the sensor If a problem is found and cannot be correct...

Page 120: ...eck the interconnect card If correct reinstall the envelope feeder and continue with step 3 3 Autoconnect on the envelope feeder Check for damage to the connector or contacts If you find damage replace the damaged cable connector assembly Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages J1 3 measures 5 V dc J1 5 measures 5 V dc J1 7 measures 24...

Page 121: ...e the envelope feeder option FRU Action 1 DC feed motor assembly Check the motor and motor cable for loose wires or poor connections Make sure the motor cable is connected to the envelope system board If correct replace the envelope feeder option FRU Action 1 Clutch latch assembly Check the clutch latch assembly to make sure it moves freely If correct replace the envelope feeder option FRU Action ...

Page 122: ...eeder option FRU Action 1 Envelopes Check the envelopes being used in the feeder Check for signs of the envelopes being stuck together or signs of glue Make sure the flaps are not interleaved If the envelopes meet the guidelines and are properly loaded go to step 2 2 Deflector Check the deflector gap adjustment The adjustment may be too wide If the deflector gap adjustment is correct go to step 3 ...

Page 123: ... that the fuser to fuser lamp cable is installed correctly to the fuser top cover assembly If incorrect install correctly if correct go to step 2 2 AC line voltage CAUTION When taking measurements for AC power observe all safety precautions Check the AC line voltage to make sure it is within operating specification If incorrect inform the customer if correct go to step 3 3 LVPS CAUTION When taking...

Page 124: ...f any problems are found replace the fuser top cover assembly If no problem is found check the fuser to system board DC cable for correct installation at J1 on the fuser control card If no problem is found check the fuser to system board cable for correct installation at J10 on the system board 7 Error code 920 06 displayed LVPS System board System board to LVPS cable Carefully check the installat...

Page 125: ...CN1 3 on the connector see the connector locations at Low voltage power supply removal on page 4 54 If incorrect replace the LVPS assembly see Low voltage power supply removal on page 4 54 if correct go to step 4 4 LVPS LVPS fuser AC cable CAUTION When taking measurements for AC power observe all safety precautions Disconnect the AC line cord from the printer Disconnect the LVPS to fuser cable fro...

Page 126: ...he fuser assembly Check the hot roll hot roll bearings and the area around the thermistor for any signs of excessive heat If a problem is found replace the thermistor If no problem is found go to step 2 2 Fuser top cover assembly thermistor Turn the printer off and disconnect the fuser to system board cable from J10 on the system board Check the resistance between pins J10 3 and J10 4 The resistan...

Page 127: ...f J10 on the system board If all cables are installed correctly go to step 2 2 Fuser top cover assembly thermistor thermistor cable assembly Turn the printer off and disconnect the thermistor cable from J5 on the fuser board Measure the resistance between the two pins on the thermistor cable if the resistance measures infinity open circuit replace the fuser top cover assembly 3 Fuser to system boa...

Page 128: ...fuser exit sensor cable for correct installation or for any signs of damage to the cable or connectors If no problem is found go to step 3 If a problem with the installation is found install the cable correctly If damage to the cable or connectors is found replace the cable 3 Fuser exit sensor flag Make sure the sensor flag is not binding and is operating properly If the sensor is operating proper...

Page 129: ...If damage to the cable or the connectors is found replace the cable 3 Fuser narrow media sensor flag Make sure the sensor flag is not binding and is operating properly If the sensor is operating properly go to step 4 If the sensor is not operation properly repair or replace the sensor assembly See Fuser narrow media sensor removal on page 4 34 4 Fuser assembly Fuser narrow media sensor cable Fuser...

Page 130: ...e solenoid between J4 1 and J4 2 on the fuser control board The resistance measures between 5 ohms and 10 ohms If incorrect replace the fuser assembly If correct go to step 2 2 System board Measure the voltage at the 50 V dc test point on the system board The voltage should measure approximately 50 V dc If incorrect go to step 3 If incorrect go to step 4 3 LVPS Measure the voltage at CN2 18 on the...

Page 131: ... cord If defective replace the cord If not defective check the AC input and output receptacles and wiring harness in the HCIT Repair or replace the receptacles or AC wiring harness as required Note Make sure the ground wire is installed correctly from the AC wiring harness to the frame of the HCIT and the nut and lock washer are tightened FRU Action 1 high capacity feeder autoconnect mechanical ch...

Page 132: ...e is damaged replace as necessary If no problem is found with the cable replace the high capacity feeder option control board FRU Action 1 Pass thru sensor and flag assembly The tray x option system board did not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appro...

Page 133: ...system board FRU Action 1 Lower limit switch Lower limit switch cable Check continuity of the lower limit switch If incorrect replace the switch If correct check the switch cable If incorrect replace the cable If correct replace the high capacity feeder option control board 2 High capacity feeder control board Disconnect the lower limit switch cable and check the voltage at J2 1 orange The voltage...

Page 134: ...in 2 Yellow The resistance measures between approximately 7 5 and 10 5 ohms If incorrect replace the motor assembly If correct replace the high capacity feeder option system board FRU Action 1 DC drive motor assembly high capacity feeder system board Check the voltages at J1 on the high capacity system board The voltages measure approximately as follows If any of the voltages are incorrect disconn...

Page 135: ...easure approximately 5 V dc If incorrect disconnect J4 from the board and measure the voltages again If incorrect replace the high capacity feeder option control board 2 Elevator top optical sensor cable Elevator top optical sensor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly FRU Action 1 High capacity feeder option cont...

Page 136: ...t the paper low switch cable from J3 and measure the voltage again on J3 1 If incorrect replace the high capacity feeder option control board If correct check the cable for a short between pins 1 and 2 on the cable If incorrect replace the cable If correct check the switch for a bent or deformed actuator lever or defective switch If incorrect replace the switch FRU Action 1 DC motor assembly Make ...

Page 137: ... mechanical linkage assembly Remove the left and right side covers and check all four autoconnects for damage especially the connector pins Remove the output option and check the voltages on the standard output bin autoconnect located on the top left rear of the printer Go to Autoconnect on page 5 6 If the voltages are correct reinstall the output option and note the positions of the toroids on th...

Page 138: ...ntrol board Disconnect the pass thru sensor cable and check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect check the voltage at J3 2 The voltage measures approximately 0 V dc If incorrect replace the sensor assembly If this does not fix the problem replace the high capacity output stacker option FRU Action 1 Input sensor flag Check the input sensor flag for damage and p...

Page 139: ...d wear or damage to the drive shaft bearings Check the drive roll assembly and skewed backup roller for signs of wear slick spots material buildup and oil or grease on the rollers Also check for proper operation of the paper aligning assembly Repair or replace parts as necessary FRU Action 1 Paper low sensor assembly Paper low sensor flag tray x option system board Run the Tray x Sensor Test and c...

Page 140: ...he required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting component...

Page 141: ...ny loose or worn parts in the developer drive assembly main drive gearbox or fuser Repair as necessary 2 Main drive motor assembly excessive noise gears ratcheting and so on A service error code 936 Transport Motor may be displayed Check the voltage at J20 6 on the system board It measures approximately 5 V dc when the motor is not running and goes to 0 V dc when the motor is running If incorrect ...

Page 142: ...f any button fails the Button Test check the failing button or buttons and associated parts Repair using the button kit See Operator panel buttons removal on page 4 67 If the problem remains replace the operator panel board see Operator panel board removal on page 4 66 If a 950 xx error code is displayed after replacing the operator panel go to 950 00 through 950 29 EPROM mismatch failure on page ...

Page 143: ... shield removal on page 4 76 If correct check continuity of the operator panel cable If the continuity is incorrect replace the upper front hinge assembly If the continuity is correct replace the operator panel board See Operator panel board removal on page 4 66 3 Operator panel display blank 5 beeps LED on Check for ground between J13 4 and ground If correct replace the operator panel board See O...

Page 144: ... controller board DRAM Memory Option s This service check is the same as the flash memory option service check with the following exception Run the DRAM Test on page 3 7 from the menu if the SDRAM Memory card is correctly installed and not broken or damaged If the test fails replace the SDRAM card If the problem continues replace the controller board Error Code 976 xx Network Card x x Network card...

Page 145: ...ore unless the flag is in the up position or out of the sensor slot a Remove Paper Standard Bin message does not display FRU Action 1 System board Printer fails to display Remove Paper Standard Bin message Output Bin Sensor Test fails Check the voltage at J6 1 It measures 5 V dc when the flag is in the sensor and 0 V dc when the flag is out of the sensor If the voltage does not change replace the ...

Page 146: ...heck the output expander control board cover to make sure the ESD brush ground lead is firmly attached to the output expander frame Also make sure the ESD brush is not loose FRU Action 1 Output expander option Make sure the output expander option is the only option that is not recognized by the base printer If the output expander is the only option not recognized by the printer continue with step ...

Page 147: ...option FRU Action 1 Pass thru sensor and flag assembly Control board Check the sensor flag for proper operation If correct check to make sure the pass thru sensor cable is correctly connected to J3 on the control board Disconnect the pass thru sensor cable from J3 on the control board and check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the control board If ...

Page 148: ... is correctly attached to the left side frame and the mounting screws are tight Check the alignment assembly for worn rollers contaminated rollers or binds Replace the alignment assembly if any problem is found 2 Inner deflector Check the inner paper deflector for correct installation If the deflector is bowed or not fitting correctly replace the deflector FRU Action 1 Pass thru sensor Check the p...

Page 149: ...ly Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications Paper size sensing service check Before proceeding check for the correct paper size loaded in the tray and that the tray has been set to accept the size paper loaded in the tray Paper size sensing switch chart ITC CN1 pin Signal ITC switch Paper tray size selection X is acti...

Page 150: ... and ITC switches If a problem is found repair or replace the tray assembly If no problem is found go to step 2 2 Integrated card autocompensator cable Check for correct installation of the cable at J26 on the system board If installed correctly go to step 3 If incorrectly installed install and recheck the printer 3 System board Check the continuity between J26 2 on the system board and ground It ...

Page 151: ...the paper size and corresponding paper switch from table below If the voltage on J26 does not change go to step 4 If the voltage changes recheck the printer If Tray 1Missing is still displayed replace the system board assembly 4 System board Ground the appropriate pin on connector J26 on the system board Tray 1 Missing should not be displayed If it is not displayed go to step 5 If it still display...

Page 152: ...r setup Print Resolution Set to 300 dpi print quality problems should be checked at different resolution settings Print Darkness Set to NORMAL Toner Saver Set to OFF PQET Set to OFF Fuser Temperature Set to NORMAL Test the printer using plain paper 20 lb An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page corr...

Page 153: ...ages at J22 on the system board Measure the following voltages from connector J22 to printer ground Printer Idle J15 5 measures 24 V dc Printer Printing J15 5 measures 24 V dc If the voltages at J10 5 are incorrect replace the system board 4 Front cable harness HVPS section Check the front cable harness at J15 on the system board and at CN1 on the HVPS to make sure the harness is connected properl...

Page 154: ...ms Some problems occur with printers that run a large amount of graphics in a humid environment The customer may try to improve the print quality by increasing the transfer setting Check the charge roll to make sure it is not at the end of life FRU Action 1 Printhead The printhead on this printer cannot be cleaned Try another printhead if all other attempts fail to correct a background problem 2 T...

Page 155: ...s at J15 on the system board Measure the voltages from J15 to printer ground If J15 1 voltage is incorrect check the continuity of the front harness cable J15 1 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the system board If J15 2 voltage is incorrect or if the voltage remains at 0 V dc check the cont...

Page 156: ...e parts Replace as necessary 2 Charge roll assembly Charge roll link arm Check the charge roll for toner buildup or other contamination on the outer edges that correspond to the bands on the page Check the charge links and arms for proper operation binds or incorrectly mounted counterbalance springs Repair or replace as necessary 3 HVPS Check the following voltages at J15 8 on the system board Pri...

Page 157: ...ssembly Check the connection of the transfer roll assembly cable to the transformer on the HVPS board Check the continuity of the cable from the bearing to the spade terminal on the cable If incorrect replace the right side transfer arm assembly If correct replace the HVPS 3 Printhead A contaminated printhead may be the cause of light print If no other cause is found install a new printhead FRU Ac...

Page 158: ...for proper seating of the signature button cartridge cable to the system board Service error code Explanation 1 Error code 931 xx No first HYSNC Signal Error Code 932 Lost HYSNC These errors usually indicate a failure in the HYSNC signal to the printhead Check the continuity of the cables connected to J2 and J4 on the system board If incorrect replace the defective cable The voltage at J4 1 measur...

Page 159: ...Diagnostic information 2 123 ...

Page 160: ...2 124 Service Manual ...

Page 161: ...Diagnostic information 2 125 ...

Page 162: ...before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in...

Page 163: ...n of the front harness cable to make sure it is properly seated into the toner sensor If correct at both the sensor and system board J15 check the continuity of the cable If incorrect replace the cable 3 Toner sensor The toner sensor cable is part of the front harness and part of connector J15 on the system board Check the voltage at J15 11 It reads approximately 5 V dc If incorrect replace the sy...

Page 164: ...t is fastened and locked in the down position If the arm is not locked down make sure the arm is not broken and locks into the EP frame correctly Check the left transfer arm assembly spring for proper operation 3 Right transfer arm assembly Check the right transfer arm assembly to make sure it is fastened and locked in the down position If the arm is not locked down make sure the arm is not broken...

Page 165: ...gnostics Mode group contains the settings and operations used while manufacturing and servicing the printer See Diagnostics mode on page 3 2 for more information Configuration Menu 1 Turn off the printer 2 Press and hold and 3 Turn on the printer 4 Release the buttons when Performing Self Test displays The Configuration Menu group contains a set of menus settings and operations which are infrequen...

Page 166: ... page 3 5 PRINT TESTS Tray 1 See Input source tests on page 3 6 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed MP Feeder Env Feeder if installed Prt Quality Pgs See Print quality pages Prt Quality Pgs on page 3 6 HARDWARE TESTS Panel Test See Panel Test on page 3 7 Button Test See Button Test on page 3 7 DRAM Test See DRAM Test on page 3 7 CACHE Test Parallel Wrap ...

Page 167: ...f installed BASE SENSOR TEST See BASE SENSOR TEST on page 3 18 Toner Input Output DEVICE TESTS Quick Disk Test if installed See Quick Disk Test on page 3 18 Disk Test Clean if installed See Disk Test Clean on page 3 19 Flash Test if installed See Flash Test on page 3 19 PRINTER SETUP Defaults See Defaults on page 3 20 Page Count See Page Count on page 3 20 Perm Page Count See Perm Page Count perma...

Page 168: ...the appears next to Quick Test b Press The message Quick Test Printing appears on the display Retain this page to determine the changes you need to make to the margins settings EP SETUP EP Defaults See EP Defaults on page 3 22 Fuser Temp See Fuser Temperature Fuser Temp on page 3 22 Fuser Page Count See Fuser Page Count on page 3 22 Warm Up Time See Warm Up Time on page 3 22 Transfer See Transfer ...

Page 169: ...nt the Quick Test page Note Print the Quick Test Page on letter or A4 paper 1 Select REGISTRATION from DIAGNOSTICS 2 Press until the appears next to Quick Test The message Quick Test Printing appears on the display Once the Quick Test Page completes printing the Registration screen displays again T xxx B xxx L xxx R xxx Variable Description Value Direction of change B Bottom margin 20 to 20 Each i...

Page 170: ...lity Pgs The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled The print quality pages consist of three pages Page one contains a mixture of graphics and text Pages two and three only contain graphics If duplex is turned on the pages are duplexed The Print Quality Test pages are printed in English and must al...

Page 171: ...ct DRAM Test from the menu The message DRAM Test Testing displays Then the message Resetting Printer appears and the power indicator light blinks red 2 Turn the printer off and on While the DRAM test executes the power indicator blinks green The following type of message appears xxx represents the installed DRAM size P represents the number of times the memory test has passed and finished successf...

Page 172: ... the printer off Parallel Wrap tests This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signal is tested Use Parallel Wrap for the standard parallel port Parallel 1 Wrap if a parallel port is available by PCI slot 1 or Parallel 2 Wrap if a parallel port is available by PCI slot 2 To run the Parallel Wrap tests 1 Disconnect the parallel interface cable...

Page 173: ...e test stops The power indicator goes on solid and the final results display To stop the test before completion press Stop The message Serial Wrap x Test Canceled displays and the printer returns to the HARDWARE TESTS menu DUPLEX TESTS Quick Test duplex This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a ...

Page 174: ...00 of an inch The Top Margin duplex range is 20 to 20 and the default value is 0 An increase moves the top margin down and widens the top margin A decrease moves the top margin upward and narrows the top margin 4 Press 5 Print the Quick Test duplex again to verify the adjustment Repeat if necessary Sensor Test duplex This test is used to determine whether or not the duplex sensors and switches are...

Page 175: ...CC average PWM for the low speed portion of the test The results should be in the range of 3A through 5D inclusively hex DD minimum PWM for the low speed portion of the test The results should be in the range of 11 through 1F inclusively hex Ignore bytes EE and FF If the test fails remove the drive belt from the duplex DC motor and run the motor test again For the duplex DC motor to pass the test ...

Page 176: ...emove the media from the duplex unit and clear the message on the operator panel by pressing Back or Stop Duplex Feed 2 This test feeds a blank sheet of paper to the duplex paper stop position 2 This test can be run using any of the supported paper sizes To run the Duplex Feed 2 Test 1 Select Duplex Feed 2 from DUPLEX TESTS The power indicator blinks while the paper is feeding and the message Dupl...

Page 177: ... is used to determine if the input tray sensors are working correctly To run the Input Tray Sensor Test 1 Select the Sensor Test from INPUT TRAY TESTS 2 Select the input source from the sources displayed on the Sensor Test menu All installed sources are listed 3 Select the sensor to test Various sources have different combinations of sensors See the table below sensor selected OP displays Empty In...

Page 178: ...r Continuous Single feeds one sheet of media from the selected source Continuous media continues feeding from the selected source until Stop is pressed Press Back to return to OUTPUT BIN TESTS Feed To All Bins This test can be used to verify that the printer can feed media to the standard bin or any installed output options No information will be printed on the test pages as the printhead is not e...

Page 179: ...ates Open when the flag is out of the sensor and Closed when the flag is in the sensor 5 Press Back or Stop to exit the test Sensor Test Output Expander This test is used to determine whether or not the output bin sensor is working correctly for the output expander if installed 1 Select Sensor Test from OUTPUT BIN TESTS 2 Select Output Bin x x number of the output option to be tested from Sensor T...

Page 180: ...ilbox 1 Select Sensor Tests from OUTPUT BIN TESTS 2 Select Output Bin x x number of the output option to be tested The following screen is displayed Output Bin x P1 OP P2 OP L NL passThru 5 bin mailbox pass thru sensor shows Open or Closed mailboxEmpty 5 bin mailbox empty sensor shows Normal for a normal level NearFull for nearly full and Full for full 3 Manually actuate each of the sensors of the...

Page 181: ...Diagnostic aids 3 17 ...

Page 182: ...t the test DEVICE TESTS Quick Disk Test This test performs a non destructive read write on one block per track on the disk The test reads one block on each track saves the data and proceeds to write and read four test patterns to the bytes in the block If the block is good the saved data is written back to the disk To run the Quick Disk Test 1 Select Quick Disk Test from DEVICE TESTS The power ind...

Page 183: ...Disk Test Clean Failed appears If the message indicates failure the disk is unusable Flash Test This test verifies the functioning of the flash device by writing and reading data on the flash to test the flash Warning This test destroys all data on the flash because the flash is unformatted at the end of the test To reformat the flash the servicer or the user must use FORMAT FLASH from the UTILITI...

Page 184: ...permanent page count can only be viewed and cannot be changed To view the permanent page count 1 Select Perm Page Count from PRINTER SETUP 2 Press Back to return to PRINTER SETUP Serial Number The serial number can only be viewed and cannot be changed To view the serial number 1 Select Serial number from PRINTER SETUP 2 Press Back to return to PRINTER SETUP Envelope Enhance This setting affects th...

Page 185: ...elect a digit or character to change press or until the digit or character is underlined To change a digit or character press to increase or to decrease the value When the last digit is changed press to validate the Configuration ID 1 If Invalid ID appears the entry is discarded and the previous Configuration ID 1 is displayed on the screen If the process is successful Submitting Selection appears...

Page 186: ... 2 Press Back to return to PRINTER SETUP Warm Up Time You can change the amount of time the printer warms up before allowing pages to print by changing this setting from 0 to 5 The factory sets the warm up at 0 or no warm up time This time period lets the backup roll heat up and helps reduce curl in some environments Transfer The transfer can be adjusted to Low Medium or High The default setting i...

Page 187: ...d 9xx error messages are stored in the event log To view the event log 1 Select Display Log from EVENT LOG Up to three error codes display at a time Press or to view additional error codes 2 Press Back to return to the EVENT LOG menu Print Log Additional diagnostic information is available when you print the event log from DIAGNOSTICS rather than CONFIG MENU The Event Log printed from DIAGNOSTICS ...

Page 188: ... viewed log and the printed log information 1 Select Clear Log from the Event Log menu 2 Select YES to clear the Event Log or NO to exit the Clear Log menu If YES is selected Deleting EVENT LOG displays on the screen Press Back to return to EVENT LOG EXIT DIAGNOSTICS This selection exits Diagnostics mode and Resetting the Printer displays The printer performs a POR and the printer returns to norma...

Page 189: ...t is installed See Maintenance kit on page 6 1 for the part number Maint Cnt Value See Maintenance page count Maint Cnt Value on page 3 25 Reset Maint Cnt See Maintenance page counter reset Reset Maint Cnt on page 3 26 Prt Quality Pgs See Print quality pages Prt Quality Pgs on page 3 26 SIZE SENSING See SIZE SENSING on page 3 27 Panel Menus See Panel Menus on page 3 27 PPDS Emulation See PPDS Emul...

Page 190: ...int quality pages Prt Quality Pgs on page 3 6 Additional configuration information may be included on the print quality pages which is not included on the print menu page To print the Print Quality Test Pages select Prt Quality Pgs from CONFIG MENU The message Printing Quality Test Pages is displayed The following is printed Settings from EP SETUP from DIAGNOSTICS Fuser temperature warm up time tr...

Page 191: ...the user to enable or disable PPDS emulation data stream When this setting is enabled the following settings are also changed SmartSwitch settings for each port are turned off The printer language is changed to PPDS Emulation Users can still switch languages on the operator panel and through the PJL data stream Download Emuls Demo Mode There is a built in demonstration mode The settings allow you ...

Page 192: ...og from EVENT LOG 2 Press Back or Stop to return to EVENT LOG Note An event log printed from the CONFIG MENU will not contain debug information or secondary codes for 900 service errors However the event log printed from DIAGNOSTICS mode does include this information Paper Prompts When a tray is out of the indicated paper size a prompt is sent to the user to load paper in a tray This setting contr...

Page 193: ...e the value and to increase the value The values range from 1 to 10 and 5 is the default value LCD Contrast When this setting is selected the operator panel displays a gray bar with a slider representing the values As the values are decreased the bar appears darker and when the values are increased the bar appears lighter Changes to this setting immediately change the operator panel The range of v...

Page 194: ...his test page must be printed on letter legal or A4 paper To print the Menu Settings Page 1 Select the TESTS MENU 2 Select Print Menus from the TESTS MENU The page contains the following information A list of all the printer settings contained in the operator panel menus and their values A list of the installed options and features such as RAM memory cards optional input paper trays envelope feede...

Page 195: ...ke the D roll this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness High normal force is one of the most significant contributors to double feeding paper The pick arm is counterbalanced by an extension spring located on the pick arm to reduce weight in the rest state This spring is factory set to exert no more tha...

Page 196: ... interface transmit signal serial interface receive signal and two ground pins The duplex option receives the 24 V dc from the base printer for the duplex motors and also converts the voltage to 5 V dc for duplex electronics Duplex chassis grounding is provided from the printer to the duplex option through a ground spring attached to the frame and base of the printer The ground connection is autom...

Page 197: ...ter inside the printer and at the rear of the printer Jams in the front of the printer occur in the input options or the duplex tray Jams inside the printer occur in two locations and require the removal of the print cartridge Jams can also occur at the rear of the printer or in one of the output options Note The following clearing jam instructions may seem out of sequence However they have been g...

Page 198: ...move the paper from the multipurpose feeder 2 Flex fan and restack the media and place it into the multipurpose feeder 3 Load the print media 4 Slide the side guide toward the inside of the tray until it lightly rests against the edge of the media 5 Press ...

Page 199: ...e pulled out remove the envelope feeder a Lift the envelope feeder up out of the printer and then set it aside b Remove the envelope from the printer If you cannot remove the envelope the print cartridge will have to be removed See 200 and 201 Paper Jam Remove Cartridge on page 3 37 for more information c Reinstall the envelope feeder Make sure it snaps into place 3 Flex and stack the envelopes 4 ...

Page 200: ... more than one tray To clear these areas 1 Open the printer paper tray and remove any jammed media 2 Open the duplex tray To remove the media pull up 3 Open any optional trays beginning at the top and remove any jammed media Pull the print media either up or down If it does not pull easily one way try the other way ...

Page 201: ...r button A to lower the tray remove the jam and make sure the stack of print media is neat and aligned 5 Press 200 and 201 Paper Jam Remove Cartridge 1 Push the release latch and lower the multipurpose feeder 2 Push the release latch and open the top front cover CAUTION The inside of the printer is hot ...

Page 202: ...aside Note Do not leave the cartridge exposed to light for extended periods Note The print media may be covered with unfused toner which can stain garments and skin 5 Pull the print media up and toward you Warning If the print media does not move immediately when you pull stop pulling You need to access the print media from the printer rear door 6 Reinstall the toner cartridge 7 Close the top fron...

Page 203: ... 202 Paper Jam Open Rear Door 1 If the paper is exiting the printer pull the media straight out and press Otherwise continue with step 2 2 Open the printer rear door 3 Remove the jammed media 4 Close the rear door 5 Press ...

Page 204: ...23x Paper Jam Open Duplex Rear Door 1 Open the duplex rear door 2 Remove the jammed media Depending on the media location pull the media either up or down 3 Close the duplex rear door Make sure it snaps into place 4 Press ...

Page 205: ...Pages 3 42 through 3 44 have been removed from this document intentionally Diagnostic aids 3 41 ...

Page 206: ...city in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical gr...

Page 207: ...d assembly adjustment whenever you remove or replace the printhead assembly or loosen the mounting screws Install the new printhead with the three mounting screws centered in the slots in the printhead frame assembly Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots It is necessary to perform a registration adjustment before locking down the t...

Page 208: ... the reference adjustment screw out far enough to allow the alignment assembly to be removed from the printer It is not necessary to completely remove the screw 4 Install the new alignment assembly Turn the reference screw clockwise with a 7 mm nut driver until it touches the back of the reference plate and tighten the nut with a 5 5 mm wrench The reference adjustment screw can be adjusted without...

Page 209: ...handholds on the side of the printer Make sure your fingers are not under the printer when you lift or set the printer down Note Some removal procedures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement Covers removals Fuser wiper cover assembly removal 1 Squeeze the two latches together a...

Page 210: ...edrive cap cover removal 1 Pull up on the right side of the redrive cap cover to remove 2 Remove the redrive cap cover Paper support removal 1 Raise the paper support and lift to release the latches 2 Remove the paper support ...

Page 211: ...4 6 Service Manual Left door removal 1 Open the upper and lower front covers 2 Press the two left door latch buttons A and open the left door 3 Release the top hinge from the latch ...

Page 212: ...Repair information 4 7 4 Lift the door to release the bottom from the pin B and remove the door Redrive door 1 With the redrive door partially open lift and free the left side 2 Remove the redrive door ...

Page 213: ... redrive cap See Redrive cap cover removal on page 4 5 2 Open the upper and lower front covers 3 Remove the print cartridge 4 Remove the right front cover mounting screw A 5 Remove the redrive door See Redrive door on page 4 7 6 Remove the two screws B ...

Page 214: ...Repair information 4 9 7 Remove the right rear cover mounting screw C 8 Press the two latches to remove the redrive assembly ...

Page 215: ...front of the right cover 10 Pull up and out on the right cover to release the three cover retainers E at the bottom Note When replacing the right side cover make sure the three cover retainers are correctly located in the appropriate slots in the right side frame ...

Page 216: ...components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it can not be used in another printer It must be returned to the manufacturer 1 Open the lower front cover 2 Open the upper front cover 3 Remove ...

Page 217: ...nt cover remove the upper front cover outer bezel and upper front cover latch Otherwise carefully set the upper front cover aside to avoid scratching the bezel or loosening the latch and spring Note When removing the upper front cover outer bezel use care not to lose or drop the clear plastic inner bezel Installation notes Lift the paper support before installing the upper front cover Make sure th...

Page 218: ... information 4 13 Upper front cover latch removal 1 Remove the upper front cover 2 Remove the screw A holding the latch and spring to the upper front cover Installation note The spring B is installed as shown ...

Page 219: ... 3 Remove the two small upper front cover outer bezel mounting screws A 4 Pull up to remove the outer bezel NOTE If available place a soft clean cloth on the open lower front bezel The clear inner bebel B is not connect and may fall The cloth may prevent scratches on the bezel 4 14 Service Manual ...

Page 220: ...e tray to a position that allows the left and right tray hinge slots A to align with the D shape mounting posts B Pull upward on each tray hinge to remove the tray from the two mounting posts Warning Be careful not to break or stress the hinges 2 Remove the multipurpose tray lower front cover assembly ...

Page 221: ...age 4 67 3 Remove the two screws A holding the top of the left handle holder in place 4 Use the tab B to lift out the left handle holder Right cover handle holder removal 1 Remove the right side cover See Right cover removal on page 4 8 2 Remove the two screws A holding the top of the right handle holder in place 3 Lift out the right handle holder ...

Page 222: ...n 4 17 Left and right frame extensions 1 Remove the toner cartridge 2 Turn the printer on its back 3 Remove the two screws A holding the right frame extension 4 Remove the two screws B securing the left frame extension ...

Page 223: ...Redrive assembly removal on page 4 74 2 Remove the screw A securing the pass thru plate 3 Carefully remove the plate until it is loose 4 Remove the fuser to system board DC cable B secured through the plate Note Note the routing of the fuser card to system board DC cable ...

Page 224: ...page 4 8 3 Remove the paper support See Paper support removal on page 4 5 4 Remove the redrive cap See Redrive cap cover removal on page 4 5 5 Press the fuser wiper cover latch and remove the cover 6 Remove the screw A at the rear of the printer and the larger screw B at the front on the right side 7 Remove the two mounting screws C from the left side A ...

Page 225: ...Service Manual 8 Remove the paper bin full sensor flag from the mounting bracket See Paper bin full sensor flag removal on page 4 70 9 Unlatch the front right and front left cover posts and remove the cover ...

Page 226: ...2 Remove the inner shield 3 Remove the gear guard 4 Remove the power takeoff shaft and spring A through the bottom of the printer 5 Place your thumb on the top of the gear and press firmly down and away Note You need to exert firm pressure to snap the bevel gear out ...

Page 227: ... and press or pull into position Note You should hear two distinct snaps If you only hear one the bevel gear is only partially engaged and you should continue to press until the second snap is heard Very firm pressure is required CAUTION Do not brace your hands below the bevel gear itself When the gear double snaps into place it may pinch your hand 5 Install the power takeoff shaft and spring 6 In...

Page 228: ... J2 on the system board 3 Remove the three screws securing the cartridge duct A Note It may be necessary to pull the main fan cable B up and out of the way to remove the duct 4 Reconnect the printhead laser cable Note Be sure to reposition the main fan cable if you moved it out of the way when removing the duct ...

Page 229: ...B securing the developer drive assembly 3 Remove the developer drive assembly 4 Remove the developer drive coupler kit See Developer drive coupler kit removal on page 4 25 Installation 1 Place the developer coupler into the main motor drive shaft 2 Place the developer drive shaft on the developer drive 3 Align the developer drive shaft with the coupler 4 Be sure to replace the screws in the same p...

Page 230: ...ge 4 24 2 Remove the shaft drive and coupler ESD cover removal 1 Open the multipurpose tray and remove the tray from the two mounting posts See Multipurpose feeder lower front cover assembly removal on page 4 15 2 Carefully lift the latch on the left A and remove the ESD cover Note Be careful not to stress the hinge on the right B ...

Page 231: ...u begin 1 Remove the fuser wick assembly cover See Fuser wiper cover assembly removal on page 4 4 2 Remove the redrive assembly See Redrive assembly removal on page 4 74 3 Remove the fuser mounting screws A 4 Disconnect the fuser to LVPS AC cable B from the fuser lamp connector C ...

Page 232: ...mp AC and the DC cable 6 Pull the cables free and remove the fuser Installation notes 1 When you reinstall the fuser be sure to route the fuser to LVPS AC cable A through the channel B on the right side frame above the LVPS under the clip C over the LVPS and through the notch in the frame D 2 Route the fuser lamp cable through the opening in the fuser E ...

Page 233: ...placing the LVPS Fuser exit sensor removal 1 Remove the fuser See Fuser assembly removal on page 4 26 2 Disconnect the fuser exit cable A from the fuser control board 3 Remove the screw B securing the cover containing the fuser exit sensor flag and spring 4 Release the two clips C holding the sensor in the bracket 5 Unplug the fuser exit sensor cable from the sensor ...

Page 234: ...ecurely into the cover 2 Connect the fuser exit sensor cable 3 Snap the bottom fastener of the sensor cover into place in the lower exit guide and use a small flat bladed screwdriver to ease the sensor cover into the clips 4 Replace the screw securing the sensor cover Note Make sure the flag moves properly ...

Page 235: ...nsor See Fuser exit sensor removal on page 4 28 2 Note the position of the spring A in relation to the flag B 3 Carefully ease the right arm C until the fuser exit sensor cover releases the flag and spring Spring replacement 1 Place the spring on the left pin A 2 Set the tang B on the flag ...

Page 236: ... the bent end C of the spring to add tension place the pins between the sensor cover arms and rest the bent end against the sensor cover frame Note After replacing the sensor flag and spring make sure the flag moves freely and returns ...

Page 237: ...er assembly removal on page 4 26 2 Disconnect the fuser lamp AC cable from the right side of the top cover assembly 3 Remove the two screws A from the right side fuser lamp contact cover Warning Take care when removing the screw as the lamp is under spring tension When the contact is released damage to the lamp or contact may occur 4 Remove the left lamp contact assembly A 202 ...

Page 238: ...ng the lamp from the fuser Grip the lamp by the ceramic end piece and remove it from the fuser assembly Be careful not to touch the glass as skin oils and acids can reduce the life of the lamp Use the following table to identify and install the correct lamp Description P N Fuser Lamp 115 V 40X0122 Fuser Lamp 220 V 40X0123 ...

Page 239: ...o the fuser 3 With a thumbnail release the catches B holding the sensor cover to the lower exit guide C in place Note You may need to move the narrow media flag out of the way to remove the sensor 4 Disconnect the fuser narrow media cable at the sensor 5 Release the catches holding the sensor in the cover Note Hold the narrow media flag out of the way to remove the sensor from the cover ...

Page 240: ...e way to clip the sensor securely into the cover 2 Connect the fuser narrow media cable 3 Snap the bottom fastener of the sensor cover into place in the lower exit guide and rock the cover up until the top fastener snaps securely 4 Replace the screw securing the sensor cover ...

Page 241: ...See Fuser narrow media sensor removal on page 4 34 2 Note the position of the spring A in relation to the flag B 3 Carefully ease the right arm C of the sensor cover just far enough apart to release the flag and spring Spring replacement 1 Place the spring on the left pin A 2 Set the tang B on the flag ...

Page 242: ...otate the bent end C of the spring to add tension place the pins between the sensor cover arms and rest the bent end against the sensor cover frame Note After replacing the sensor flag and spring make sure the flag moves properly ...

Page 243: ... Redrive assembly removal on page 4 74 3 Remove the right side cover See Right cover removal on page 4 8 4 Disconnect the fuser to LVPS AC cable A from the fuser lamp connector on the fuser and remove the cable through the cable retainer B and the lower rectangular opening C in the fuser frame 5 Remove the pass thru plate See Pass thru plate on page 4 18 6 Disconnect the LVPS to system board DC ca...

Page 244: ...Note The LVPS assembly may be difficult to remove from the printer Do not use excessive force in the removal 8 Remove the fuser to LVPS AC cable Installation 1 Plug in the fuser to LVPS AC cable A into the LVPS 2 Route the cable through the channel B on the right side frame above the LVPS under the clip C over the LVPS and through the notch in the frame D ...

Page 245: ...Manual 3 Route the cable through the lower rectangular opening E 4 Connect the fuser to LVPS AC cable to the fuser lamp connector F Note Be sure to connect the fuser to system board DC cable after replacing the LVPS ...

Page 246: ...nter before you begin 1 Remove the fuser assembly See Fuser assembly removal on page 4 26 2 Note the thermistor cable routing A and disconnect the thermistor cable at the fuser control board 3 Disconnect the AC fuser lamp cable B from the top right side of the fuser cover ...

Page 247: ...er lamp contact cover D 5 Release the latch E and remove the cover 6 Remove the screw F on the left side and the screw G on the right side that attach the fuser upper cover assembly to the fuser frame 7 Remove screw H that attaches the side fuser lamp contact to the fuser top cover F G H ...

Page 248: ...emoval on page 4 77 3 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 47 4 Lift the left side of the fuser transfer plate A and move the plate to the left to clear the right side from its mounting 5 Remove the screw that attaches the transfer plate ground wire to the center pan 6 Remove the fuser transfer plate 7 Remove the screw that attaches the deflector ca...

Page 249: ...nd inner shield removal on page 4 76 2 Remove the developer drive 3 Disconnect the gear release link A from the hole in charge roll link B Note Lift the upper front cover to make it easier to remove the link 4 Rotate the link to disconnect the link from the main drive assembly 5 Remove the gear release link ...

Page 250: ... power in order to perform the task 1 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 47 2 Remove the right side cover See Right cover removal on page 4 8 3 Disconnect the HVPS cable from the HVPS at connector A 4 Disconnect the transfer roll cable B from the HVPS board Warning Use care when disconnecting the cable from the transformer on the HVPS The cable an...

Page 251: ...4 46 Service Manual 5 Remove the HVPS mounting screws C 6 Slide the HVPS to the left to release the mounting tab from the center pan and remove the HVPS ...

Page 252: ...9 3 Remove the MPF lower deflector assembly See MPF lower paper deflector on page 4 61 4 Place the printer on its side 5 Gently pry the inner paper deflector from the left and right mounting posts A located on the bottom of the printer and remove the deflector 6 Disengage the two latches B on the upper part of the deflector from the upper edge of the frame C and lift to remove A B C C ...

Page 253: ...age 4 79 2 Loosen the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 15 3 Remove the inner paper deflector Inner paper deflector assembly removal on page 4 47 4 Disconnect the input sensor cable A from the input sensor B 5 Release the input sensor from its mounting and remove ...

Page 254: ...mbly removal 1 Remove the paper tray 2 Remove the left door See Left door removal on page 4 6 3 Remove the outer shield See Outer shield removal on page 4 67 4 Place the printer on its back 5 Disconnect the autocompensator motor cable A from the system board J24 ...

Page 255: ...he larger loop attaches to the side frame 7 Remove the C clip D that rests against the right side frame from the autocompensator pivot shaft 8 Disconnect the autocompensator sensor cable E from the assembly 9 Remove the autocompensator assembly mounting screw F 10 Slide the shaft to the right and push the shaft from the outside of the frame 11 Remove the integrated tray autocompensator assembly ...

Page 256: ...e the integrated tray and look underneath the printer for the autocompensator arm Pull the arm down 2 Press on the end of the tab A and pull the pick roll off the arm Repeat this step for the pick roll on the other side Next gently release the autocompensator arm Discard the used pick rolls ...

Page 257: ...pick roll and align it with the tab on the arm There are two arrows on each pick roll Make sure the bottom arrow faces you as you align the recessed area with the tab 3 Push the pick roll onto the arm with the tab aligned Repeat this step on the other side to install the other pick roll 4 Gently release the autocompensator arm Insert integrated tray ...

Page 258: ... after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it can not be used in another printer It must be returned to the manufacturer Warning Observe all ESD precautions while handling ESD sensitive parts See Handling ESD sensitive parts ...

Page 259: ...he right side cover See Right cover removal on page 4 8 3 Remove the pass thru plate See Pass thru plate on page 4 18 4 Remove the LVPS mounting screws A from the rear of the center pan 5 Disconnect the LVPS to system board cable The cable is difficult to disconnect There are catches B that firmly hold latches on the LVPS card connector C 4 54 Service Manual ...

Page 260: ...y far enough out from the right side of the printer to disconnect the fuser to LVPS AC lamp cable D Warning The LVPS assembly may be difficult to remove from the printer Do not use excessive force in the removal 7 Remove the low voltage power supply ...

Page 261: ...ld removal on page 4 67 3 Remove the two screws A securing the main fan cap 4 Remove the main fan cap 5 Clip the cable tie B Note Be careful not to damage any of the cables Note the location of the cable tie for later replacement 6 Disconnect the main fan to the system board C at J4 7 Remove the main fan ...

Page 262: ...ssembly removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 76 2 Remove the screw securing the gear guard A 3 Remove the power take off shaft and spring See Power takeoff shaft and spring removal on page 4 72 4 Remove the developer drive assembly See Developer drive assembly removal on page 4 24 ...

Page 263: ...4 58 Service Manual 5 Lift and remove the cables from the cable hooks B 6 Remove the ground cable screw C 7 Remove the main drive assembly mounting screws D ...

Page 264: ...mbly Warning Whenever the main drive assembly is removed from the printer it must be handled very carefully Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage It is also very important not to let any dirt paper staples or other material come in contact with the grease in the gears Note Be sure the main drive assembly gear shaft aligns with th...

Page 265: ...eflector See MPF lower paper deflector on page 4 61 4 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 79 5 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 47 6 Remove the MPF solenoid assembly See MPF solenoid assembly removal on page 4 62 7 Remove the C clip A 8 Remove the washer and set it aside 9 Remove the MPF arm asse...

Page 266: ...1 Installation note Note the order of C clips bushing and washer when you reinstall MPF lower paper deflector 1 Remove the MPF lower cover 2 Remove the four screws securing the MPF lower paper deflector 3 Remove the defector ...

Page 267: ...k roll off the shaft MPF solenoid assembly removal 1 Open the left door 2 Remove the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 15 3 Remove the MPF lower paper deflector See MPF lower paper deflector on page 4 61 4 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 79 5 Remove the C clip A on the left side A ...

Page 268: ...ation 4 63 6 Press the clips on the end of the shaft to remove the MPF tires B 7 Remove the C clip C on the shaft 8 Remove the bushing D Note The bushing fits into a detent E in the frame of the MPF arm assembly B C ...

Page 269: ...ve the C clip securing the MPF solenoid assembly on the shaft Note This C clip is very difficult to locate and remove 11 Pull the shaft assembly G to the right until the left end of the shaft is clear of the frame and slide the MPF solenoid assembly from the shaft F ...

Page 270: ...Repair information 4 65 Installation note Be careful not to lose the washer H that is between the MPF solenoid assembly and the C clip It belongs to the MPF arm assembly H ...

Page 271: ...replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it can not be used in another printer It must be returned to the manufacturer 1 Remove the upper front cover See Upper...

Page 272: ...moval on page 4 66 2 Remove the functional rubber sheet A and the rubber dome sheet B 3 The navigation buttons and the select button can be removed by releasing the clips C on the back of the upper front cover Outer shield removal 1 Remove the left door See Left door removal on page 4 6 2 Loosen the outer shield mounting screws A and remove the shield by sliding up A 202 A 202 ...

Page 273: ... See Upper paper deflector assembly removal on page 4 79 2 Remove the inner paper deflector assembly See Inner paper deflector assembly removal on page 4 47 3 Release the input paper sensor from its mounting and remove 4 Remove the left door 5 Remove the paper alignment assembly mounting screws A ...

Page 274: ... the paper alignment assembly reference adjustment screw B through the left frame and remove the screw 7 Remove the paper alignment assembly Note Do the Paper alignment assembly adjustment on page 4 3 when you reinstall the assembly B ...

Page 275: ...assembly removal on page 4 74 3 Remove the fuser wiper cover assembly See Fuser wiper cover assembly removal on page 4 4 4 Remove the mounting screws A from the left side 5 Lift the left corner of the laser cover assembly cover to access the flag 6 Use your thumb to bend the paper full flag assembly slightly to unlatch it from the mounting bracket A ...

Page 276: ... inner shield See System board and inner shield removal on page 4 76 2 Remove the paper size sensing board mounting screw A 3 Disconnect the paper size sensing board cable B from the board 4 Remove the paper size sensing board from the latch C 5 Remove the paper size sensing board C A B ...

Page 277: ...4 72 Service Manual Power takeoff shaft and spring removal Remove the power takeoff shaft and spring A through the bottom of the printer ...

Page 278: ...ove the laser cover See Laser cover removal on page 4 19 2 Disconnect the printhead cable A from the printhead assembly 3 Remove the three printhead mounting screws B and remove the printhead Note Do the Printhead assembly adjustment on page 4 2 whenever you remove or replace the printhead assembly or loosen the mounting screws ...

Page 279: ...Redrive assembly removal 1 Remove the redrive door assembly 2 Remove the redrive exit cover 3 Remove the redrive assembly mounting screws A 4 Release the redrive assembly mounting latches B and remove the redrive assembly ...

Page 280: ... outer system board shield See Outer shield removal on page 4 67 5 Disconnect signature button cable from connector J14 on the system board 6 On models 200 210 400 410 remove the two screws A securing the blower duct 7 Remove the signature button contact assembly mounting screw B 8 Remove the assembly signature button contact assembly Note Be sure to route the cable in the same location as shown C...

Page 281: ...be used in another printer It must be returned to the manufacturer Warning Observe all ESD precautions while handling ESD sensitive parts See Handling ESD sensitive parts on page 4 1 1 Remove the outer shield See Outer shield removal on page 4 67 2 Disconnect all cables from the system board Note Sometimes cables may be difficult to remove Be careful not to damage the connectors 3 Remove all featu...

Page 282: ...emove the toner sensor Transfer roll assembly removal Warning Be careful when handling the transfer roll Wrap a piece of plain white paper around the charge roll to prevent contamination or damage 1 Open the upper front cover and remove the print cartridge 2 Unsnap the transfer roll assembly from the left pivot arm 3 Lift the transfer roll assembly toward the left and remove it from the printer ...

Page 283: ...ch hinge 4 Detach the two springs B from the upper front cover hinges 5 Detach spring C from the left side of the hinge assembly 6 Remove the cover closed switch assembly 7 Disconnect the operator panel cable from the operator panel board 8 Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket D 9 Lift the left pivot arm from the b...

Page 284: ...ver are easily stressed or broken 2 Lift the left side to release the small tab A on the left and the MPF flag B and slide the upper paper deflector assembly to the right to unlatch the hooks C on the right Note Be careful not to put too much stress on the small tab A on the right 3 Lift to remove the upper paper deflector assembly Installation note Make sure the MPF flag B is in place ...

Page 285: ...4 80 Service Manual 4061 xx0 USB board assembly removal 1 Remove the upper front cover 2 Disconnect the USB cable from the USB board assembly 3 Remove the screw A securing the USB board assembly ...

Page 286: ...Connector locations and connections 5 1 5 Connector locations and connections Connections System board ...

Page 287: ... Level 2 2 Video3 3 Ground 4 5PHead 5 LPOW 6 LADJ 7 LPOW FB 8 LENA J3 Printhead HSYNC mirror motor 1 Ground 2 HSYNC CN 3 HSYNC ID 4 5 V dc 5 6 7 8 9 10 11 12 J4 Main fan 1 FANSTALL 2 Ground 3 MAINFAN J5 Cartridge fan 1 CARTFANSTAIL 2 Ground 3 CARTFAN J6 Hopper full output bin sensor 1 HOP FULL 2 Ground 3 HOP LED J7 USB port 1 2 3 4 5 6 7 ...

Page 288: ... 11 I2C DAT L5 J13 Operator panel 1 I2C DAT 2 5 V dc 3 I2C CLK 4 Ground 5 PANEL INT 6 3 3 V dc 7 Ground J14 Signature button 1 SM Cart 2 Ground J15 HVPS 1 ATSERVO 2 TXENABLE 3 XFR 4 24 V dc switched 5 CHARGE 6 Ground 7 DEV 8 Ground input sensor 9 INPUTSENSX 10 5 V dc switched Cartridge toner wheel sensor 11 5 V dc 12 TONER WHEELX 13 Ground System board see System board on page 5 1 Connector Pin no...

Page 289: ...2 BLDC_HALL 1 3 BLDC_HALL 2 4 BLDC FG 5 Ground 6 5 V dc switched 7 BLDC WIND 8 BLDC WIND 1 9 BLDC WIND 2 J21 Autoconnect top 1 Ground 2 5 V dc fused 3 Ground 4 24 V dc PTC OPT J23 MPF pick solenoid 1 MPFPick 2 24V dc J24 Autocomp motor 1 24 V dc 2 AUTOCOMP J25 Autoconnect bottom front 1 Ground 2 24VPTCOPT System board see System board on page 5 1 Connector Pin no Signal ...

Page 290: ...LVPS 1 5 V dc 2 5 V dc 3 5 V dc 4 Ground 5 Ground 6 Ground 7 Ground 8 Ground 9 Ground 10 Ground 11 24 V dc RAW 12 Ground 13 24 V dc RAW 14 24 V dc RAW 15 ZEROXING R 16 24 V dc RAW 17 HEAT 18 HEAT 19 Ground 20 L FAN DRV J28 MPF paper out 1 MPF POUT 2 Ground 3 MPF LED J29 Top options 1 RXD1R 2 Ground 3 TXD1BR 4 Ground System board see System board on page 5 1 Connector Pin no Signal ...

Page 291: ...B DI 3 USB DI 4 Ground 5 Ground Printhead fan 1 24V dc 2 PH FAN Connector Pin no Signal static Bottom autoconnect 1 24 V dc 2 0 V dc 3 5 V dc 4 0 V dc 5 0 V dc 6 0 V dc Front autoconnect 1 0 V dc 2 0 V dc 3 0 V dc 4 5 V dc 5 0 V dc 6 24 V dc System board see System board on page 5 1 Connector Pin no Signal ...

Page 292: ... Board Top autoconnect 1 0 V dc 2 5 V dc 3 0 V dc 4 0 V dc 5 0 V dc 6 5 V dc 7 0 V dc 8 24 V dc Fuser Board not a FRU Connectors J1 System board J2 Narrow media sensor J3 N A J4 Solenoid J5 Exit sensor J6 Thermistor Connector Pin no Signal static ...

Page 293: ...round 3 prtrxd 4 Ground J3 Pass thru sensor 1 Ground 2 Paper Present 3 RVsnsr J4 DC motor 1 mtrout1 2 mtrout2 3 Ground 4 Ground 5 tach 6 5 V dc J5 Bin full near full dual sensor 1 Ground 2 Ground 3 binful 4 binful 5 RVsnsr J6 Jumper connector 1 Upper unit 2 Upper Lower Unit 3 Lower Unit J6 1 M S J6 connector jumper locations High capacity stacker board Pin 1 Pin 2 Pin 3 Upper unit board X X Not us...

Page 294: ... High voltage power supply Interconnect card Connector CN no Signal CN1 System board 1 Developer PWM 2 24 V dc Return 3 Charge PWM 4 24 V dc IN 5 TX PWM 6 TX Enable 7 TX CUR PWM 8 SVRO OUT Connector Pin no Signal J1 1 J2 1 U 7 5 HY 3 KJ 7 1 ...

Page 295: ...no Signal CN1 Fuser lamp AC 1 AC fuser lamp 2 Not used 3 AC fuser lamp CN2 DC output 1 5 V dc 2 5 V dc 3 Ground 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 Heat on 10 5 V dc 11 5 V dc 12 Ground 13 Ground 14 Ground 15 Ground 16 24 V dc 17 ZC Out 18 42 V dc 1 1 ...

Page 296: ...Ground 5 N C J2A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J2B 1 prtxdout 2 Ground 3 prtrxd 4 Ground J3 Pass thru sensor 1 Ground 2 Paper Present 3 RVsnsr J4 DC motor 1 mtrout1 2 mtrout2 3 Ground 4 Ground 5 tach 6 5 V dc J5 Bin full near full dual sensor 1 Ground 2 Ground 3 binful 4 binful 5 RVsnsr J6 Jumper connector 1 Not used 2 Not used 3 Not used 5 2 2 5 5 5 9 5 2 5 1 3 ...

Page 297: ...5 12 Service Manual ...

Page 298: ...Connector locations and connections 5 13 ...

Page 299: ...5 14 Service Manual ...

Page 300: ...top cover and the power supply cover Possible safety exposure from any non Toshiba attachments Lubrication specifications No requirements for this printer Scheduled maintenance Maintenance kit The operator panel displays the message 80 Scheduled Maintenance at each 300K page count interval It is necessary to replace the fuser assembly transfer roller charge roll and pick tires at this interval to ...

Page 301: ...6 2 Service Manual ...

Page 302: ...n refers to the number of units used in the option and does not include the base machine Units kit or pkg refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the parts description column indicates the part is contained in a parts packet...

Page 303: ...7 2 Service Manual Assembly 1 Covers ...

Page 304: ...0 1 1 Upper front cover assembly with Lexmark logo including Operator panel board 1 Stop button 1 Menu button 1 Back button 1 LED cap 1 Navigation buttons 4 Number pad buttons 1 Navigation select button 1 Number pad rubber dome sheet 1 USB board 1 Functional rubber sheet 1 12 40X0014 1 1 Operator panel outer bezel with Lexmark logo T640 12 40X0233 1 1 Operator panel outer bezel with Lexmark logo T...

Page 305: ...7 4 Service Manual Assembly 2 Frame 1 ...

Page 306: ... plate 200 210 400 410 2 40X0225 1 1 Right side hand holder 3 4 4 Parts packet PP 40X0165 4 40X0024 1 1 Right frame extension 200 210 400 410 5 40X0026 1 1 Right side frame ground contact 6 40X0025 1 1 Left frame extension 200 210 400 410 7 40X0060 1 1 External ground clip 8 40X0331 1 1 Left side hand holder 9 40X0285 1 1 Frame clip ...

Page 307: ...7 6 Service Manual Assembly 3 Frame 2 ...

Page 308: ...40X0046 1 1 Paper size sensing board assembly 10 40X0049 1 1 Gear release link 11 40X0053 1 1 Main fan with cable 250 sheet output 11 40X0054 1 1 Main fan with cable 500 sheet output 12 40X0212 1 1 Main fan duct 200 210 400 410 13 40X0211 1 1 Main fan duct 000 010 14 40X0052 1 1 Standard bin level sensor bracket 15 40X0051 1 1 Standard bin level sensor 16 40X0264 1 1 Standard bin level sensor cabl...

Page 309: ...7 8 Service Manual Assembly 4 Frame 3 ...

Page 310: ...nput sensor toner sensor cable assembly 8 40X0036 1 1 Toner sensor assembly 9 40X0306 1 1 High voltage contact kit including Charge roll contact 1 Doc TAR Dev contact 3 PC drum contact 1 Screw 5 Screw block 4 10 40X0213 1 1 Tray bias assembly 11 40X0021 2 1 Cartridge holddown assembly 12 40X0040 1 1 Upper paper feed deflector 13 40X0041 1 1 Inner paper feed deflector 000 010 13 40X0042 1 1 Inner p...

Page 311: ...7 10 Service Manual Assembly 5 Printhead ...

Page 312: ...r Units mach Units kit or pkg Description 4 1 40X0061 1 1 Laser cable assembly 2 Parts packet printhead mounting screw PP 40X0165 3 40X0062 1 1 Printhead assembly includes all cables CAUTION The printhead is not a serviceable FRU Do not disassemble the printhead ...

Page 313: ...7 12 Service Manual Assembly 6 Paper feed autocompensator ...

Page 314: ...ts packet bellcrank assembly 250 sheet tray 000 010 Bellcrank 1 Spring 1 2 40X0069 1 1 Parts packet bellcrank assembly for 500 sheet tray 200 210 400 410 Bellcrank 1 Spring 1 3 40X0070 2 2 Pick roll assembly 4 40X0071 1 1 Paper out flag 250 sheet tray 000 010 4 40X0072 1 1 Paper out flag 500 sheet tray 200 210 400 410 5 40X0073 1 1 Paper low out sensor card assembly 6 Parts packet hanger PP 40X016...

Page 315: ...7 14 Service Manual 4061 xx0 Assembly 7 Paper feed multipurpose feeder ...

Page 316: ... arm assembly 3 40X0076 1 1 Pick roll assembly 4 40X0077 1 1 Multipurpose feeder paper out flag 5 Parts packet lower deflector mounting screw 8 mm PP 40X0165 5 Parts packet lower deflector mounting screw 12 mm PP 40X0165 5 1 Parts packet frame mounting screw PP 40X0165 6 40X0082 2 1 Pick roll shaft bushing 7 40X0083 1 1 Multipurpose feeder frame assembly with solenoid NS Parts packet pick roll sha...

Page 317: ...7 16 Service Manual Assembly 8 Paper feed alignment ...

Page 318: ... 1 1 Paper feed alignment assembly paper feed 2 Parts packet clip ref ground mounting screw PP 40X0165 3 40X0085 1 1 Reference ground clip 4 40X0086 Parts packet reference adjust Screw paper reference adjust 1 Washer paper reference adjust 1 Nut paper reference adjust 1 NS Parts packet alignment asm mounting screw PP 40X0165 ...

Page 319: ...Page 7 19 has been removed from this document intentionally 7 18 Service Manual ...

Page 320: ...7 20 Service Manual Assembly 10 Integrated 500 sheet paper tray ...

Page 321: ...er Units mach Units kit or pkg Description 10 1 40X0098 1 1 Tray assembly 500 sheet tray 2 40X0099 1 1 Side restraint 3 40X0182 4 1 Wear strip 4 40X0103 1 1 Pass thru plate 500 sheet tray 5 40X0183 1 1 Wear plate 500 sheet tray 6 40X0105 2 1 Restraint pad 7 40X0106 1 1 Back restraint ...

Page 322: ...7 22 Service Manual Assembly 11 Drives Main drive and developer drive ...

Page 323: ... 1 1 Power takeoff shaft 500 sheet 200 210 400 410 3 40X0112 1 1 Power takeoff shaft spring 4 40X0113 1 1 Bevel gear with grease packet and washer Bevel gear 1 Instruction sheet 1 Grease packet 1 5 40X0114 1 1 Developer drive assembly 6 40X0115 Parts packet developer drive Developer drive shaft 1 shaft coupler gear 55 1 7 3 Parts packet developer drive ground screw PP 40X0165 NS 4 Parts packet gea...

Page 324: ...7 24 Service Manual Assembly 12 Hot roll fuser ...

Page 325: ...121 1 Fuser cover assembly kit including Thermistor 1 Thermostat 1 Left and right fuser lamp contact assemblies 1 5 Parts packet fuser mounting screw PP 40X0227 6 40X0239 1 Exit sensor flag spring kit including Spring 1 Flag 1 7 40X0236 1 1 Exit narrow media sensor cover 8 Parts packet PP 40X0165 9 40X0125 1 1 Exit sensor 10 40X0330 1 1 Exit sensor cable 11 40X0238 1 1 1 Narrow media flag spring k...

Page 326: ...7 26 Service Manual Assembly 13 Transfer charging ...

Page 327: ...bly dual 3 40X0129 1 Parts kit right side charge roll link assembly 4 40X0130 1 1 Transfer roll assembly 5 40X0131 1 1 Transfer roll assembly right arm 6 40X0132 1 1 Transfer roll right spring 7 40X0133 1 1 Transfer pivot shaft 8 40X0134 1 1 Transfer roll left spring 9 40X0135 1 1 Transfer roll left arm NS 1 Parts packet charge roll screw PP 40X0165 NS 1 Parts packet C clip pivot shaft PP 40X0165 ...

Page 328: ...7 28 Service Manual Assembly 14 Electronics power supplies ...

Page 329: ...ark Finland France Germany Greece Hungary Ireland Italy Medmark 1 and 2 Netherlands Norway Paraguay Poland Portugal Russia Slavic countries Spain Sweden Turkey and UK 2 40X0293 1 1 Power cord set 8 ft right angle Arabic Austria Belgium Bluemark CIS Czechoslovakia Finland France Germany Greece Hungary Ireland Italy Medmark 1 and 2 Netherlands Poland Portugal Russia Slavic countries Spain Turkey and...

Page 330: ...7 30 Service Manual Note ...

Page 331: ...1 slot 000 010 3 40X0140 1 1 System board assembly non network 000 Board ID Q0016021 3 40X0141 1 1 System board assembly non network 200 Board ID Q0016022 3 40X0142 1 1 System board assembly non network 400 Board ID Q0016023 4 40X0143 1 1 System board assembly network 010 Board ID Q0016001 4 40X0144 1 1 System board assembly network 210 Board ID Q0016002 4 40X0145 1 1 System board assembly network...

Page 332: ...7 32 Service Manual Assembly 16 Electronics shields ...

Page 333: ...t INA cover mounting screw PP 40X0165 2 Parts packet outer shield mounting screw PP 40X0165 2 Parts packet inner shield mounting screw PP 40X0165 3 40X0149 1 1 Inner shield assembly 2 slot 200 210 400 410 4 40X0153 1 1 INA flat cover blank 5 40X0152 1 1 Ethernet shield blank 000 200 400 6 40X0154 1 1 Inner shield assembly 1 slot 000 010 7 40X0222 1 1 Outer shield 1 slot 000 010 ...

Page 334: ...Cabling diagrams 1 Asm Index Part number Units mach Units kit or pkg Description 17 1 40X0223 1 1 HVPS input sensor toner sensor cable assembly 2 40X0160 1 1 MPF sensor cable 3 40X0034 1 1 Signature button contact assembly with cable ...

Page 335: ...agrams 2 Asm Index Part number Units mach Units kit or pkg Description 18 1 40X0061 1 1 Laser printhead cable assembly 2 40X0074 1 1 Autocompensator motor cable 3 40X0046 1 1 Paper size sensing board Tray 1 autocompensator paper out low cable ...

Page 336: ...7 36 Service Manual Assembly 19 Cabling diagrams 3 ...

Page 337: ...it or pkg Description 19 1 40X0034 1 1 Signature button contact assembly with cable 2 40X0156 1 1 Bottom front autoconnect cable assembly 3 40X0223 1 1 HPVS input sensor toner sensor cable assembly 4 40X0157 1 1 Top autoconnect cable assembly 5 40X0224 1 1 LVPS to system board cable assembly ...

Page 338: ...7 38 Service Manual Assembly 20 Cabling diagrams 4 ...

Page 339: ...g Description 20 1 40X0006 1 1 Upper front cover hinge assembly includes USB cable A 1 Operator panel cable B 1 Cover open switch cable C 1 2 40X0162 1 1 System board to fuser board cable assembly 3 40X0163 1 1 Fuser AC lamp to LVPS cable assembly 4 40X0226 1 1 Fuser connector fuser AC to fuser lamp ...

Page 340: ...7 40 Service Manual Assembly 21 Cabling diagrams 5 ...

Page 341: ...or pkg Description 21 1 40X0083 1 1 Frame assembly with solenoid and cable 2 40X0159 1 1 Main drive motor cable assembly 3 40X0035 1 1 EP fan with cable 250 sheet 000 010 3 40X0249 1 1 EP fan with cable 500 sheet 200 210 400 410 4 40x0053 1 1 Main fan 250 sheet 4 40X0054 1 1 Main fan 500 sheet ...

Page 342: ...7 42 S ervice Manual THE FOLLOWING PAGE 7 43 HAS BEEN OMITTED FROM THIS MANUAL INTENTIONALLY ...

Page 343: ...embly 500 sheet 4 56P1228 1 1 Bellcrank spring arm 5 56P2540 1 1 Bellcrank spring 500 sheet option tray 6 99A0070 1 2 Pick roll assembly 7 56P4127 1 1 Option pass thru sensor 8 99A0275 1 1 Power takeoff spring 9 99A0447 1 1 Drive shaft 500 sheet 10 56P4128 1 1 Bin low sensor with cable 11 56P4143 1 1 Base assembly 500 sheet 12 56P4145 1 1 Paper out arm 500 sheet drawer 13 99A0063 1 1 Switch activa...

Page 344: ...ption Units kit or pkg Description 25 1 1 1 Complete tray assembly 500 sheet 2 56P4137 1 1 Side restraint 500 sheet tray 3 99A0292 1 4 Wear strips 4 56P4196 1 1 Pass thru plate 5 99A0120 1 2 Restraint pad 6 56P4195 1 1 Wear plate 500 sheet 7 56P4147 1 1 Back restraint 500 sheet tray 20G0890 ...

Page 345: ...7 46 Service Manual Assembly 26 Duplex option Asm Index Part number Units option Units kit or pkg Description 26 1 1 1 1 Duplex assembly 500 sheet 20G0888 ...

Page 346: ...Parts catalog 7 47 Assembly 27 Envelope feeder Asm Index Part number Units option Units kit or pkg Description 1 1 Complete envelope option 2 56P4229 1 1 Slide out support 20G0891 27 ...

Page 347: ...7 48 S ervice Manual Pages 7 49 through 7 57 of this manual have been omitted intentionally ...

Page 348: ...7 58 Service Manual Assembly 35 High capacity feeder 1 ...

Page 349: ...0681 4 1 Wear strip 4 56P4155 1 1 Front door assembly 5 56P4157 1 2 Door hinge 6 4 1 Parts packet 6 32 hinge mounting nut PP 99A0676 7 4 1 Parts packet hinge mounting flat washer PP 99A0677 8 4 1 Parts packet hinge mounting star washer PP 99A0677 9 56P4142 1 1 2000 sheet option control card assembly 10 4 4 Parts packet card asm mounting PP 99A0675 11 4 4 Parts packet card asm mounting screw PP 99A...

Page 350: ...7 60 Service Manual Assembly 36 High capacity feeder 2 ...

Page 351: ...y 36 High capacity feeder 2 Asm Index Part number Units option Units kit or pkg Description 36 1 99A0654 1 1 Paper low switch 2 Parts packet nuts PP 99A0676 3 99A1808 1 1 AC external jumper cord 4 99A0667 1 1 Power supply board ...

Page 352: ...7 62 Service Manual Assembly 37 High capacity feeder 4 Asm Index Part number Units option Units kit or pkg Description 37 1 99A0275 1 1 Power takeoff spring 2 99A0272 1 1 Drive shaft 250 sheet ...

Page 353: ...eder 5 Asm Index Part number Units option Units kit or pkg Description 38 1 3 Parts packet auto comp assembly mounting screw PP 99A0263 2 56P4162 1 1 Pick arm assembly 2000 sheet 3 99A0070 2 2 Pick roll assembly 4 56P4127 1 1 Option pass thru sensor ...

Page 354: ...7 64 S ervice Manual Pages 7 65 thru 7 70 ofthis manual were omitted intentionally ...

Page 355: ...ice menus 3 1 Button Test 3 7 description function 2 2 operator panel button removal 4 67 upper front cover including buttons 7 3 upper front panel button kit 7 3 C cable diagrams 7 34 7 35 7 36 7 38 7 40 CACHE Test 3 8 Card Stock Label Guide 1 8 card stock guidelines 1 18 cartridge duct removal 4 23 characteristics print media 1 15 code update 3 1 Configuration ID 3 21 configuration menu accessin...

Page 356: ...5 PRINT TESTS input source 3 6 Prt Quality Pgs 3 6 PRINTER SETUP Configuration ID 3 21 Defaults 3 20 Edge to Edge 3 21 engine settings 3 20 Envelope Enhance 3 20 Model Name 3 20 Page Count 3 20 Par x Strobe Adj 3 21 Perm Page Count 3 20 Serial Number 3 20 REGISTRATION 3 4 Diverter Test 3 16 DRAM Test 3 7 duplex option parts catalog 7 46 service check 2 82 duplex tests Duplex Feed 1 3 12 Duplex Fee...

Page 357: ...er deflector removal 4 47 inner shield parts catalog 7 32 removal 4 76 input sensor removal 4 48 input sensor tray tests 3 13 input source tests 3 6 input tray feed test 3 13 installation bevel gear 4 22 fuser assembly 4 27 fuser exit sensor 4 29 fuser exit sensor spring 4 30 fuser narrow media sensor 4 35 fuser narrow media spring replacement 4 36 pick roll assembly integrated tray autocompensato...

Page 358: ...r Page Count 3 22 Page Count 3 20 permanent page count 3 20 Panel Test 3 7 paper and media specifications 1 8 paper bin full sensor flag 4 70 paper deflector assembly inner 4 47 upper 4 79 paper feed jams 200 and 201 Paper Jam Remove Cartridge 3 37 202 Paper Jam Open Rear Door 3 39 23x and 24x jams 3 36 23x Paper Jam Open Duplex Rear Door 3 40 250 Paper Jam Check MP Feeder 3 34 260 Paper Jam Check...

Page 359: ... removal 4 8 upper front cover 4 11 upper front cover latch 4 13 upper front cover outer bezel 4 14 developer drive assembly 4 24 developer drive coupler kit 4 25 ESD cover 4 25 fuser 4 26 fuser cover removal 4 41 fuser exit sensor 4 28 fuser exit sensor flag and spring 4 30 fuser lamp 4 32 fuser narrow media flag and spring 4 36 fuser narrow media sensor 4 34 fuser to LVPS AC cable 4 38 fuser tra...

Page 360: ... system board 2 126 toner sensor 2 127 transfer roll 2 128 service error codes 2 8 shield inner shield 4 76 outer 4 67 signature button contact assembly parts catalog 7 34 removal 4 75 specifications acoustics 1 7 dimensions 1 5 electrical 1 6 environment 1 7 media 1 8 memory configuration 1 4 operating clearances 1 4 power requirements 1 6 print media 1 15 resolution 1 3 speed and performance 1 3...

Page 361: ...7 upper paper deflector 4 79 user attendance messages 2 32 user line 2 link messages 2 43 user status displays 2 31 W warm up time 3 22 warning messages user status displays 2 31 wiper cover 4 4 wrap tests 3 8 ...

Page 362: ...I 8 Service Manual ...

Page 363: ...ter spring 7 7 40X0029 Redrive assembly 250 in 250 out 000 010 7 7 40X0030 Redrive assembly 500 in 500 out 200 210 400 410 7 7 40X0032 Transfer deflector 7 7 40X0033 Machine mounting pad 7 9 40X0034 Signature button contact assembly with cable 7 34 7 37 40X0034 Signature button sensor assembly 7 9 40X0035 EP DC fan assembly 000 010 7 9 40X0035 EP fan with cable 250 sheet 000 010 7 41 40X0036 Toner...

Page 364: ...7 15 40X0083 Frame assembly with solenoid and cable 7 41 40X0083 Multipurpose feeder frame assembly with solenoid 7 15 40X0084 Paper feed alignment assembly paper feed 7 17 40X0085 Reference ground clip 7 17 40X0086 Parts packet reference adjust 7 17 40X0087 Integrated 250 sheet tray 7 19 40X0090 Back restraint 250 sheet tray 7 19 40X0091 Restraint pad 7 19 40X0092 Side restraint 250 sheet tray 7 ...

Page 365: ...0X0163 Fuser AC lamp to LVPS cable assembly 7 39 40X0165 Parts packet 7 5 7 7 7 9 7 25 7 29 40X0165 Parts packet alignment asm mounting screw 7 17 40X0165 Parts packet C clip pivot shaft 7 27 40X0165 Parts packet charge roll screw 7 27 40X0165 Parts packet clip ref ground mounting screw 7 17 40X0165 Parts packet developer drive ground screw 7 23 40X0165 Parts packet frame mounting screw 7 15 40X01...

Page 366: ...ight angle Brazil 7 29 40X0260 Power cord set 8 ft right angle 13 amp United States 7 29 40X0263 Pass thru plate 250 sheet tray 7 19 40X0264 Standard bin level sensor cable 7 7 40X0265 PRESCRIBE card assembly 7 31 7 69 40X0266 Single byte forms card assembly 7 69 40X0267 Double byte forms card assembly 7 69 40X0271 Power cord set Hong Kong 7 29 40X0281 Power cord set Taiwan 7 29 40X0285 Frame clip...

Page 367: ...y assembly option 250 sheet 7 43 56P4126 Pick arm assembly 7 42 56P4127 Option pass thru sensor 7 42 7 44 7 63 56P4128 Bin low sensor with cable 7 42 7 44 56P4129 Paper out arm 250 sheet 7 42 56P4130 Side restraint 250 sheet tray 7 43 56P4131 Back restraint 250 sheet tray 7 43 56P4132 Output paper level flag 7 48 56P4133 Stud assembly 7 42 56P4137 Side restraint 500 sheet tray 7 45 56P4139 Pick ar...

Page 368: ... ac 200 210 400 410 7 29 56P4234 LVPS 220 V ac 000 010 7 29 56P4235 Right side cover 7 49 56P4240 115 V Maintenance kit 6 1 56P4241 220 V Maintenance kit 6 1 56P4242 100 V Maintenance kit 6 1 56P4243 High voltage power supply 7 29 7375084 Relocation kit 250 250 sheet printer 7 69 7375085 Relocation kit 500 500 sheet printer 7 69 99A0063 Switch activate spring 7 42 7 44 99A0070 Pick roll assembly 7...

Page 369: ... packet nuts 7 61 99A0677 Parts packet hinge mounting flat washer 7 59 99A0677 Parts packet hinge mounting star washer 7 59 99A0681 Wear strip 7 59 99A1785 Rear access door latch 7 55 7 65 99A1808 AC external jumper cord 7 61 99A1818 Wear dimple strip 7 59 99A1929 Bellcrank spring 250 sheet paper tray 7 42 99A2542 Output tray 7 65 ...

Page 370: ...I 16 Service Manual ...

Page 371: ...itch 3 2 1 COV CLOSE GND 5VDC 2 3 1 12C DAT OP Panel 5VDC GND PANEL INT 12C CLK 2 1 3 4 6 5 7 2 1 3 4 6 5 7 3 3VDC GND 4 1 2 3 5 2 5 4 3 1 5 V USB1 CN USB P1 USB P1 GND GND Fuser 2 1 5VSW GND Thump Therm CN GND Thumpret ExitSens NarrowMedia 2 1 3 4 6 8 10 5 7 9 11 2 1 3 4 6 8 10 5 7 9 11 12C CLK LS 3 3VDC 12C DAT LS 2 1 Gnd Signature Button 2 1 SM Cart 2 1 3 4 6 8 5 7 9 Main Drive Motor 2 9 8 7 6 ...

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