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Dell 5210n Mono Laser Printer, Service Manual

The Dell 5210n Mono Laser Printer is a reliable and efficient printing solution for businesses. For complete understanding and troubleshooting, download the comprehensive Service Manual from our website. This manual is available for free download, providing step-by-step instructions and helpful insights to optimize the performance of your printer.

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Parts catalog

7-59

Assembly 35: High-capacity feeder 1

Asm- 
Index

Part 
number

Units/
option

Units/ kit 
or pkg

Description

35—1

40X3249

1

1

Complete option assembly (A4)

2

99A1818

1

1

Wear dimple strip

3

99A0681

4

1

Wear strip

4

40X3254

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

40X3252

1

1

2000-sheet option control card assembly

10

99A0658

2

2

Door magnet

Summary of Contents for 5210n Mono Laser Printer

Page 1: ...Dell 5210n 5310n Service Manual 14Jan2010 ...

Page 2: ...ten permission of Dell Inc is strictly forbidden Trademarks used in this text Dell and the DELL logo are trademarks of Dell Inc Other trademarks and trade names may be used in this document to refer to the entities claiming the marks and names of their products Dell Inc disclaims any proprietary interest in trademarks and trade names other than its own ...

Page 3: ...1 8 Acoustics 1 8 Media specifications 1 9 Paper and specialty media guidelines 1 9 Supported print media 1 9 Selecting print media 1 16 Paper 1 16 Paper characteristics 1 16 Weight 1 16 Unacceptable paper 1 16 Transparencies 1 17 Selecting transparencies 1 17 Envelopes 1 17 Labels 1 18 Card stock 1 19 Storing print media 1 19 Avoiding jams 1 20 Print area 1 20 Tools required 1 20 Acronyms 1 21 Di...

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 95 High capacity feeder input tray service c...

Page 5: ...STS 3 9 Quick 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 Sensor Test standard output bin 3 15 Sensor Test Output Expander 3 15 Sensor Test high capacity output stacker 3 ...

Page 6: ...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 menu settings page 3 30 Theory 3 3...

Page 7: ...holder removal 4 17 Left and right frame extensions 4 18 Pass thru plate 4 19 Laser cover removal 4 20 Bevel gear removal 4 22 Cartridge duct removal 4 24 Developer drive assembly removal 4 25 Developer drive coupler kit removal 4 26 ESD cover removal 4 26 Fuser assembly removal 4 27 Fuser exit sensor removal 4 29 Fuser exit sensor flag and spring removal 4 31 Fuser lamp removal 4 33 Fuser narrow ...

Page 8: ...ser Board 5 7 High capacity output stacker 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 ...

Page 9: ...ity feeder 1 7 58 Assembly 37 High capacity feeder 3 7 62 Assembly 38 High capacity feeder 4 7 63 Assembly 39 Kiosk vertical and horizontal paper adapters 7 64 Assembly 40 StapleSmart finisher I 7 65 Assembly 41 StapleSmart finisher 2 7 66 Assembly 42 StapleSmart finisher 3 7 67 Assembly 43 StapleSmart finisher 4 7 68 Assembly 44 Options 7 69 Appendix A Options and features A 1 Installing input op...

Page 10: ...x Service Manual Linking trays A 17 Identifying and linking output bins A 18 Linking output bins A 20 Index I 1 Part number index I 9 ...

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: ...lt er en 5 milliwatt galliumarsenid laser som arbejder på bølgelængdeområdet 770 795 nanometer Lasersystemet og printeren er udformet således at mennesker aldrig udsættes for en laserstråling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchapter ...

Page 14: ...arlige Skriveren inneholder internt en klasse IIIb 3b laser som består av en gallium arsenlaserenhet som avgir stråling i bølgelengdeområdet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I nivå under vanlig bruk vedlikehold som utføres av brukeren eller foreskrevne serviceoperasjoner Avís sobre el Làser Segons ha estat cer...

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

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

Page 17: ...s d entretien et de réparation de ce produit s adressent uniquement à un personnel de maintenance qualifié Le démontage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez ...

Page 18: ...el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltajede la parte del equipo con laque está t...

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: ... messages service checks and diagnostic aids to determine the printer problem and repair the failure After you complete the repair perform tests as needed to verify the repair See Start on page 2 1 Model name Configuration Machine type The Dell 5210n and 5310n laser printers are letter quality page printers designed to attach to IBM compatible The Dell 5210n and 5310n laser printers are available ...

Page 22: ... Print Servers Forms card single byte and Simplified Chinese Media handling operations 250 and 500 sheet paper trays of A4 letter A5 B5 Executive folio statement and legal size 250 sheet universally adjustable tray 250 and 500 sheet paper drawers 400 sheet universally adjustable tray 2000 sheet high capacity feeder Envelope feeder Output expander High capacity output stacker StapleSmart Finisher 5...

Page 23: ...ire furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other configurations Tray 1 integrated tray or standard tray Multipurpose feeder Operator panel Standard output bin Tray 1 integrated tray or standard tray 5 Bin Mailbox StapleSmart Finisher Envelope feeder Duplex unit Tray 2 250or500sheets Tray 3 250or500sheets Tray 4 250or...

Page 24: ...t print 1200 dpi 600 dpi 1200 dpi 600 dpi 1200 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...

Page 25: ... Measurement Left and right side 12 in 30 48 cm Front 20 in 50 8 cm Rear 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 drawers output expander high capacity output stacker or StapleSmart finisher Optional 128MB 256MB and 512MB SDRAM DIMMs are available from Dell The memory options are Optional flash memory ...

Page 26: ... 8 in 173 2 mm 15 6 in 398 mm 14 9 in 374 mm 7 0 lb 3 2 kg 5 Bin Mailbox 13 1 in 332 mm 15 7 in 399 mm 12 2 in 310 mm 7 9 lb 3 6 kg High capacity output stacker 11 4 in 290 mm 15 7 in 399 mm 18 in 457 mm 10 lb 4 5 kg StapleSmart finisher 9 0 in 228 6 mm 17 6 in 447 7 mm 19 5 in 495 3 mm 13 lb 5 9 kg Envelope option closed position 7 72 in 196 mm 4 lb 1 8 kg Envelope option support fully extended 1...

Page 27: ...l 220 to 240 V ac at 50 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 Idle average power Printing maximum current 4 1 A 4 1 A 230 V 8 0 A 8 0 A 120 V 8 9 A 8 9 A 100 V Pow...

Page 28: ...34 000 feet 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 32 dBA 4 7 Bels Simplex printing 54 dBA 6 8 Bels Duplex printing 57 dBA N M Bels 30 dBA 4 5 Simplex printing 55 7 0 Duplex printing 58 N M Note ...

Page 29: ...s for both input and output trays and bins Print media sizes Print media weights Media weights supported in optional output bins Media sizes supported in the finisher Media weights supported in the finisher Note If you use a print media size not listed select the next larger size Print media sizes Print media size 3 indicates support Dimensions UAT universally adjustable tray 250 sheet tray 500 sh...

Page 30: ...190 5 mm 3 875 x 7 5 in 9 Envelope 98 4 x 225 4 mm 3 875 x 8 9 in 10 Envelope 104 8 x 241 3 mm 4 12 x 9 5 in DL Envelope 110 x 220 mm 4 33 x 8 66 in C5 Envelope 162 x 229 mm 6 38 x 9 01 in B5 Envelope 176 x 250 mm 6 93 x 9 84 in Print media sizes continued Print media size 3 indicates support Dimensions UAT universally adjustable tray 250 sheet tray 500 sheet tray 250 sheet drawer option 250 UAT o...

Page 31: ...Standard output bin Output expander 5 bin mailbox High capacity output stacker StapleSmart Finisher Standard Offset Stapled Paper Card stock Transparencies Vinyl labels1 2 Paper labels1 Polyester label1 Dual web and integrated label1 1 Printing label applications on the printer requires a special label fuser cleaner which prevents duplexing The label fuser cleaner is included with a special label ...

Page 32: ...bels maximum2 Pa per 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 lb bo...

Page 33: ...46 g m2 37 to 39 lb bond Labels maximum Paper 180 g m2 48 lb bond 180 g m2 48 lb bond Dual web paper 180 g m2 48 lb bond 180 g m2 48 lb bond Polyester 220 g m2 59 lb bond 220 g m2 59 lb bond Vinyl5 3 00 g m2 92 lb liner 300 g m2 92 lb liner Integrated forms Pressure sensitive area must enter the printer first 140 to 175 g m2 up to 47 lb bond 140 to 175 g m2 up to 47 lb bond Paper base grain long 7...

Page 34: ...6 x 330 mm 8 5 x 13 in Statement2 139 7 x 215 9 mm 5 5 x 8 5 in 7 Envelope 98 4 x 190 5 mm 3 875 x 7 5 in 9 Envelope 98 4 x 225 4 mm 3 875 x 8 9 in 10 Envelope 104 8 x 241 3 mm 4 12 x 9 5 in DL Envelope 110 x 220 mm 4 33 x 8 66 in C5 Envelope 162 x 229 mm 6 38 x 9 01 in B5 Envelope 176 x 250 mm 6 93 x 9 84 in Other Envelope 98 4 x 162 mm to 176 x 250 mm 3 87 x 6 38 in to 6 93 x 9 84 in 1 Paper pas...

Page 35: ...g m2 110 lb bond 199 g m2 110 lb bond Not recommended Tag 203 g m2 125 lb bond 203 g m2 125 lb bond Cover 216 g m2 80 lb bond 216 g m2 80 lb bond Transparencies Laser printer 138 to 146 g m2 37 to 39 lb bond 138 to 146 g m2 37 to 39 lb bond Not recommended Integrated forms Pressure sensitive area 140 to 175 g m2 up to 47 lb bond Not recommended Not recommended Paper base grain long 75 to 135 g m2 ...

Page 36: ...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 required NCR paper...

Page 37: ...parencies to 225 C 437 F Use only transparencies that are able to withstand these temperatures without melting discoloring offsetting or releasing hazardous emissions For detailed information refer to the Card Stock Transparencies can be fed automatically from the multipurpose feeder and all standard and optional trays except the 2000 sheet drawer Be careful when you handle transparencies Fingerpr...

Page 38: ...h 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 Size Type from the printer operator panel the printer driver the Local Printer Setup Ut...

Page 39: ...k from 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 contamina...

Page 40: ...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 19 Do not remove trays during a print job Push all trays in firmly after loading th...

Page 41: ...ht 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 O n Self Test PP Parts Packet PWM P...

Page 42: ...1 22 Service Manual ...

Page 43: ...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 44: ...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 45: ...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 46: ...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 47: ... Print quality black page Go to Print quality all black page on page 2 117 Print quality blank page Go to Print quality blank page on page 2 118 Print quality light print Go to Print quality light print on page 2 122 Print quality background Go to Print quality background on page 2 119 Print quality residual image Go to Print quality residual image on page 2 121 Print quality skew Go to Paper feed...

Page 48: ... 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 Symptom Action Envelopes do not feed from the envelope feeder Go to Envelope feeder service check on page 2 84 Envelopes do...

Page 49: ...able to clear or reset message POST incomplete Go to StapleSmart finisher service check on page 2 124 Paper feeds into finisher option output tray Paper is not stapled and paper does not align with the right side Go to StapleSmart finisher service check on page 2 124 Paper feeds into finisher option Paper aligns with the right side The stapler does not staple Go to StapleSmart finisher service che...

Page 50: ...e System board and inner shield removal on page 4 77 905 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 77 906 xx RIP interface driver error These errors indicate an unrecoverable system software error Replace the system board See System board and inner shield remov...

Page 51: ...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 Go...

Page 52: ...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 F...

Page 53: ...p 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 media...

Page 54: ...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 Fuser...

Page 55: ... 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 the...

Page 56: ...oll 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 count...

Page 57: ...n 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 temperatu...

Page 58: ... 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 59: ...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 Cold...

Page 60: ... 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 61: ...ply 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 62: ...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 x...

Page 63: ...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 pag...

Page 64: ...OR 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 10...

Page 65: ... 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 prin...

Page 66: ...l 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 2 128 929 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 2 128 929 67 No toner sensor transition Che...

Page 67: ...nds Defective motor Check motor cable and connections Go to Main drive service check on page 2 106 936 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 2 106 936 60 No lock detected at normal motor start Motor is type 0 Check for paper jams Gear binds Defective mo...

Page 68: ... detection Motor is type 0 Excessive gear loading in gearbox assembly Go to Main drive service check on page 2 106 939 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 77 940 00 LVPS zero crossing test failed Incorrect LVPS installed Noisy AC power so...

Page 69: ...y 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 abo...

Page 70: ...erform 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 been...

Page 71: ...bleshooting 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 77 956 00 System board This error indicates a system board processor failure Replace the system board See...

Page 72: ...ved 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 o...

Page 73: ... 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 2 117 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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...ice check on page 2 103 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 79: ...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 80: ...ton assembly service check on page 2 123 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 81: ... 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 82: ...ss the standard serial port but the port has been disabled 56 xx Serial Port x Disabled This error displays when data is sent tothe 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 83: ...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 84: ...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 85: ...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 86: ...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 2 103 200 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 87: ...rive motor error possibly due to mechanical load Main drive motor not working Go to Main drive service check on page 2 106 200 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 88: ...y removal on page 4 27 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 89: ...user assembly removal on page 4 27 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 90: ...ly removal on page 4 27 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 91: ...user assembly removal on page 4 27 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 92: ... removal on page 4 27 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 93: ...user assembly See Fuser assembly removal on page 4 27 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 94: ...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 27 If media is narrow t...

Page 95: ...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 27 Turn media over to reduce...

Page 96: ...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 97: ...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 27 Turn media over to...

Page 98: ...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 99: ...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 27 Turn media over...

Page 100: ...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 101: ...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 27 Turn media ov...

Page 102: ...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 103: ...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 27 Turn media over ...

Page 104: ...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 105: ...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 27 Tur...

Page 106: ...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 107: ...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 27 Turn media over to reduce...

Page 108: ...r any signs of debris or pieces of paper or media 202 94 Exit sensor may have bounced Fuser page count is not available Exit sensor assembly Go to Fuser exit sensor service check on page 2 92 202 96 Page is covering the exit sensor during warm up Fuser page count is not available Something is keeping the exit sensor in a covered position A page may not have been cleared from a prior jam Check the ...

Page 109: ...e go to 233 xx Jam displayed on operator panel on page 2 83 234 00 Paper did not arrive at duplex exit sensor Duplex rear door not fully latched Duplex feed system not working correctly Severely skewed media coming from the printer Check the media coming from the printer to the duplex option is not damaged or skewed If the media is not damaged or skewed try another duplex option if available If no...

Page 110: ...may be other jams in the paper path Duplex jam access tray is not fully latched Printer PTO not driving duplex feed rolls 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 installed and operating properly Try the duplex option again If it fails try another duplex option if available If ano...

Page 111: ... duplex option again If it fails try another duplex option if available If one is not available replace the duplex option 238 06 Duplex doublefeed and exit sensors 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 duplex option again If it fails try another duplex option if available If one is ...

Page 112: ...cal feed error due to belt slipping Timing error due to feed system Replace the duplex option 239 11 Sheet picked from duplex never made it to the input sensor Slowor delayed feed from the duplex unit Mechanical feed error due to belt slipping Timing error due to feed system Input sensor not working correctly Check duplex sensor cables for correct installation If no problem is found with the cable...

Page 113: ...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 52 User attendance messages paper jams and paper handling errors 2xx xx Error code Sub codes Description Possible causes Action ...

Page 114: ...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 115: ...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 116: ...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 117: ... 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 118: ... 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 57 If that does not fix the problem replace the system board See System board and inner shield removal on page 4 77 4 Main fan blades do not turn Measure the volt...

Page 119: ...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 120: ... 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 121: ...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 122: ...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 123: ... 6 If the voltage is incorrect replace the LVPS assembly See Low voltage power supply removal on page 4 55 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 124: ...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 9 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 125: ...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 126: ...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 127: ...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 128: ...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 129: ... 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 130: ...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 131: ...CN1 3 on the connector see the connector locations at Low voltage power supply removal on page 4 55 If incorrect replace the LVPS assembly see Low voltage power supply removal on page 4 55 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 132: ...the 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 resista...

Page 133: ...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 134: ...ow media sensor open FRU Action 1 Fuser exit sensor exit sensor test Enter the Diagnostic mode select BASE SENSOR TEST select the Exit Sensor to test for proper operation If the exit sensor fails the test go to step 2 If the exit sensor passes go to step 5 2 Fuser exit sensor cable Check the fuser exit sensor cable for correct installation or for any signs of damage to the cable or connectors If n...

Page 135: ...n FRU Action 1 Fuser narrow media sensor sensor test Enter the Diagnostics mode select BASE SENSOR TEST and select the NM Sensor to test it for proper operation If the narrow media sensor fails the test go to step 2 if the narrow media sensor does not pass the test go to step 5 2 Fuser narrow media sensor cable Check the fuser narrow media sensor cable for correct installation or any signs of dama...

Page 136: ... the exit sensor Check to see that the sensor flag is operating correctly If the sensor flag and hardware are operating incorrectly repair or replace the failing sensor assembly If no problem is found check the fuser for any signs of media in the fuser or any signs of toner or other contamination If a problem is found clean or remove the debris or contamination FRU Action ...

Page 137: ...f the solenoid between J4 1 and J4 2 on the fuser control board The resistance measures between 5 ohms and 10 ohms If incorrect replace the 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...

Page 138: ...d 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 check ...

Page 139: ...cable 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 a...

Page 140: ...em 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 mea...

Page 141: ...nd pin 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 dis...

Page 142: ...re 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 control ...

Page 143: ...nnect 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 M...

Page 144: ...hanical 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 7 If the voltages are correct reinstall the output option and note the positions of the toroids on the au...

Page 145: ...r control 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 a...

Page 146: ...ar 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 check...

Page 147: ...ce 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 above as a method of troubleshooting compo...

Page 148: ...oose 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 repl...

Page 149: ...rd If 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 68 If the problem remains replace the operator panel board see Operator panel board removal on page 4 67 If a 950 xx error code is displayed after replacing the operator panel go to 950 00 through 950 29 EPROM mismatch failure on p...

Page 150: ...he continuity is correct replace the operator panel board See Operator panel board removal on page 4 67 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 Operator panel board removal on page 4 67 If incorrect check the operator panel cable If the cable is incorrect replace the upper front cover hinge assembly See...

Page 151: ...disk board are correctly installed Run the Quick Disk Test on page 3 18 from the Device Test on the Diagnostics menu when a problem is suspected either with the hard disk system board or with the hard disk Note The Quick Disk Test is a non destructive test and indicates Pass or Fail If the test fails replace the hard disk If a problem still exists replace the hard disk board The Disk Test Clean on...

Page 152: ...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 sens...

Page 153: ...er Check 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 s...

Page 154: ...on 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 corr...

Page 155: ...mbly 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 t...

Page 156: ...heck 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 activate...

Page 157: ...ings 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...

Page 158: ...aper 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 displays rep...

Page 159: ...inter 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 ...

Page 160: ... 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 properly If...

Page 161: ...ustomer 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 Transfer roll assembly Check the high voltage contact from the HVPS to the transfer roll Check the tra...

Page 162: ...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 continuit...

Page 163: ...ctive 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...

Page 164: ...mbly 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 Actio...

Page 165: ...If correct replace the printhead assembly 2 Error Code 934 xx Mirror motor lost lock Error Code 935 Mirror motor unable to reach operating speed These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the system board cable or system board assembly The voltage at J5 2 measures approximately 24 V dc If incorrect replace the system bo...

Page 166: ...and cable connectors 2 Stapler motor drive assembly stapler card assembly Check the autoconnects for signs of damage especially the connector pins Remove the right side cover and check the cables at J1A J1B bottom autoconnect J14A J14B top autoconnect to the stapler card assembly to make sure they are attached securely Check the voltages at the printer top autoconnect If incorrect remove the finis...

Page 167: ...inisher is selected Note When a 900 xx Service Error is displayed during POST the failure is usually in the stapler gearbox assembly or stapler cartridge Replace the stapler option 281 xx Paper Jam The paper may jam at the upper deflector Replace the stapler option 281 xx Paper Jam paper jams into stapler output bin Replace the stapler option 282 xx Staple Jam Check Stapler displays FRU Action 1 S...

Page 168: ...er assembly to see if the flag or spring are broken or missing If any problem is found replace the stapler assembly If no problem is found continue with step 5 5 Carefully cycle the large gear on the side ofthe stapler assembly and try to free the cartridge holder assembly Note Look for staples jammed at the throat of the cartridge holder and remove any that are found Gently try to remove the cart...

Page 169: ...er 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 a printer it can not be used in another printer It must be returned to the manufacturer FRU...

Page 170: ... 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 system...

Page 171: ...sure it 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 ...

Page 172: ...2 130 Service Manual ...

Page 173: ...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 174: ... 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 175: ...eed Tests finisher on page 3 17 Sensor Test See Sensor Test finisher on page 3 17 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...

Page 176: ...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 177: ...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 178: ...ality 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 a...

Page 179: ...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 180: ... 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 181: ...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 182: ...0 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 183: ...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 184: ...move the media from the duplex unit and clear the message on the operator panel by pressing Back o r 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 185: ...mine 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 Input tray empty se...

Page 186: ...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 187: ...tes Open when the flag is out of the sensor and Closed when the flag is in the sensor 5 Press Back o r 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 188: ...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 189: ...er sizes supported by the printer To run the Feed Test select Feed Tests from FINISHER TESTS While the feed test runs the power indicator blinks and the message Feed Test Running displays During the test no buttons are active and the test cannot be stopped until the test is completed Sensor Test finisher This test can be used to verify whether or not the finisher sensors are working correctly To r...

Page 190: ...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 191: ...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 192: ...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 193: ...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 194: ... 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 195: ...nd 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 196: ... 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 197: ...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 198: ...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 199: ...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 to D...

Page 200: ...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 201: ...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 202: ...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 203: ...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 204: ... 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 205: ...idge arrows pointing downward firmly shake the print cartridge side to side and front to back several times to redistribute the toner Reinstall the cartridge and then press Repeat this procedure multiple times until the print remains faded When the print remains faded replace the print cartridge Change the Toner Darkness setting in the Quality menu Change the Brightness setting in the Quality menu...

Page 206: ...multiple times until the print remains faded When the print remains faded replace the print cartridge Streaks appear on the page The toner may be low To utilize the remaining toner remove the cartridge by gripping the handles with both hands With the cartridge arrows pointing downward firmly shake the print cartridge side to side and front to back several times to redistribute the toner Reinstall ...

Page 207: ... the print cartridge to see if it is installed correctly The job prints but the top and side margins are incorrect Make sure the Paper Size setting in the Paper menu is correct Make sure the margins are set correctly in your software application Ghost images appear Make sure the Paper Type setting in the Paper menu is correct Replace the charge rolls Replace the print cartridge Replace the photoco...

Page 208: ...ghtness Adjusts the gray value of printed graphics and pictures 6 6 0 is the default setting Contrast Adjusts the contrast of printed graphics and pictures 0 5 0 is the default setting Enhance Fine Lines and Gray Correction options Driver option Purpose Values Enhance Fine Lines A selection to enable a print mode preferable for certain files containing fine line detail such as architectural drawin...

Page 209: ... Paper jams can occur in three areas the front of the printer 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 inst...

Page 210: ...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 211: ...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 41 for more information c Reinstall the envelope feeder Make sure it snaps into place 3 Flex and stack the envelopes 4 ...

Page 212: ... 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 213: ...ed 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 3 Lift and pull the print cartridge out of the printer Warning Do not touch the photoconductor drum on the underside of the cartridge Use the cartridge handle whenever you are holding the cartridg...

Page 214: ...y 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 front cover 8 Close the multipurpose feeder 9 Press ...

Page 215: ... 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 216: ...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 217: ...her see 28x Paper Jam Check Finisher 27x Paper Jam Check Bin x To clear a jam in the output expander high capacity output stacker or the 5 bin mailbox 1 If the paper is exiting into the bin or finisher pull the media straight out and press Otherwise continue with step 2 2 Push the output bin rear door latches in toward the center The rear doors will open and drop down Note If you only have one out...

Page 218: ... and make sure all doors are secure 5 Press 28x Paper Jam Check Finisher To clear a jam in the finisher 1 Push the finisher rear door latches in toward the center The rear door will open and drop down 2 Remove the jammed media 3 Close the rear door and make sure the door is secure ...

Page 219: ...Diagnostic aids 3 47 4 Lift the front edge of the finisher output bin cover until it locks into position 5 Remove the stack of print media 6 Close the finisher output bin cover 7 Press ...

Page 220: ... position 2 Remove the print media 3 Press the latch to open the stapler access door 4 Firmly pull the colored tab to remove the staple cartridge holder from the stapler 5 Use the metal tab to lift the staple guard and then pull out the sheet of staples Discard the entire sheet 6 Remove any loose staples from the staple guard 7 Look through the clear covering on the bottom of the cartridge holder ...

Page 221: ... down on the staple guard until it snaps securely into place 9 Push the cartridge holder firmly into the stapler until the cartridge holder clicks into place 10 Close the stapler access door 11 Close the finisher output bin cover ...

Page 222: ...3 50 Service Manual ...

Page 223: ...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 224: ...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 225: ... page 3 4 Do the reference adjustment if you are sure the margins are set correctly 1 Loosen the locknut on the inside rear of the alignment assembly 2 Remove the two screws holding the alignment assembly to the left side frame 3 Back 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 Ins...

Page 226: ...he range specified in REGISTRATION on page 3 4 The reference screw can be adjusted without loosening the locknut Turn the screw a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want ...

Page 227: ...e 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...

Page 228: ...rive 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 229: ...Repair information 4 7 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 230: ...4 8 Service Manual 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 231: ...he redrive cap See Redrive cap cover removal on page 4 6 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 8 6 Remove the two screws B ...

Page 232: ...4 10 Service Manual 7 Remove the right rear cover mounting screw C 8 Press the two latches to remove the redrive assembly ...

Page 233: ...e 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 234: ...mponents 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 th...

Page 235: ...ront 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 ...

Page 236: ... Service Manual 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 237: ...the upper front cover 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 cover The clear inner bezel B is not connected and may fall The cloth may prevent scratches on the bezel ...

Page 238: ...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 239: ... page 4 69 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 9 2 Remove the two screws A holding the top of the right handle holder in place 3 Lift out the right handle holder ...

Page 240: ...nual 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 241: ...e Redrive assembly removal on page 4 75 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 242: ...ge 4 9 3 Remove the paper support See Paper support removal on page 4 6 4 Remove the redrive cap See Redrive cap cover removal on page 4 6 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 243: ...information 4 21 8 Remove the paper bin full sensor flag from the mounting bracket See Paper bin full sensor flag removal on page 4 71 9 Unlatch the front right and front left cover posts and remove the cover ...

Page 244: ...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 245: ...on 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 ...

Page 246: ...2 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 247: ...w 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 26 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...

Page 248: ... 4 25 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 16 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 249: ...you begin 1 Remove the fuser wick assembly cover See Fuser wiper cover assembly removal on page 4 5 2 Remove the redrive assembly See Redrive assembly removal on page 4 75 3 Remove the fuser mounting screws A 4 Disconnect the fuser to LVPS AC cable B from the fuser lamp connector C ...

Page 250: ... 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 251: ...replacing the LVPS Fuser exit sensor removal 1 Remove the fuser See Fuser assembly removal on page 4 27 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 252: ...urely 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 253: ...sensor See Fuser exit sensor removal on page 4 29 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 254: ...he 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 255: ...user assembly removal on page 4 27 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 256: ... 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 257: ... to 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 258: ...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 259: ...r See Fuser narrow media sensor removal on page 4 35 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 260: ...te 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 A ...

Page 261: ...ee Redrive assembly removal on page 4 75 3 Remove the right side cover See Right cover removal on page 4 9 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 19 6 Disconnect the LVPS to system board DC ...

Page 262: ...te 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 263: ...ion 4 41 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 264: ...er before you begin 1 Remove the fuser assembly See Fuser assembly removal on page 4 27 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 265: ...user 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 266: ...oval on page 4 78 3 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 48 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 cabl...

Page 267: ... and inner shield removal on page 4 77 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 268: ...ower in order to perform the task 1 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 48 2 Remove the right side cover See Right cover removal on page 4 9 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 and ...

Page 269: ...Repair information 4 47 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 270: ...3 Remove the MPF lower deflector assembly See MPF lower paper deflector on page 4 62 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 271: ... page 4 80 2 Loosen the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 16 3 Remove the inner paper deflector Inner paper deflector assembly removal on page 4 48 4 Disconnect the input sensor cable A from the input sensor B 5 Release the input sensor from its mounting and remove ...

Page 272: ...ly removal 1 Remove the paper tray 2 Remove the left door See Left door removal on page 4 7 3 Remove the outer shield See Outer shield removal on page 4 69 4 Place the printer on its back 5 Disconnect the autocompensator motor cable A from the system board J24 ...

Page 273: ... the 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 274: ...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 275: ...e 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 276: ...fter 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 on...

Page 277: ...n page 4 75 2 Remove the right side cover See Right cover removal on page 4 9 3 Remove the pass thru plate See Pass thru plate on page 4 19 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 ...

Page 278: ...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 toremove from the printer Do not use excessive force in the removal 7 Remove the low voltage power supply ...

Page 279: ...ield removal on page 4 69 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 280: ...embly removal 1 Remove the system board and inner shield See System board and inner shield removal on page 4 77 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 73 4 Remove the developer drive assembly See Developer drive assembly removal on page 4 25 ...

Page 281: ...Repair information 4 59 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 282: ...ly 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 the ...

Page 283: ... deflector See MPF lower paper deflector on page 4 62 4 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 80 5 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 48 6 Remove the MPF solenoid assembly See MPF solenoid assembly removal on page 4 63 7 Remove the C clip A 8 Remove the washer and set it aside 9 Remove the MPF arm as...

Page 284: ...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 285: ...ick 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 16 3 Remove the MPF lower paper deflector See MPF lower paper deflector on page 4 62 4 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 80 5 Remove the C clip A on the left side A ...

Page 286: ...e Manual 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 287: ...move 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 288: ...4 66 Service Manual 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 289: ...r 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 Upp...

Page 290: ...s are in a single kit 1 Remove the operator panel board See Operator panel board removal on page 4 67 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 ...

Page 291: ...Repair information 4 69 Outer shield removal 1 Remove the left door See Left door removal on page 4 7 2 Loosen the outer shield mounting screws A and remove the shield by sliding up A 202 A 202 ...

Page 292: ...ector assembly removal on page 4 48 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 6 Locate 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 reins...

Page 293: ...e assembly removal on page 4 75 3 Remove the fuser wiper cover assembly See Fuser wiper cover assembly removal on page 4 5 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 294: ...nner shield See System board and inner shield removal on page 4 77 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 295: ...Repair information 4 73 Power takeoff shaft and spring removal Remove the power takeoff shaft and spring A through the bottom of the printer ...

Page 296: ...uired 1 Remove the laser cover See Laser cover removal on page 4 20 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 297: ...5 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 298: ...uter system board shield See Outer shield removal on page 4 69 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 w...

Page 299: ...t 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 69 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 fea...

Page 300: ...ove 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 301: ...each 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...

Page 302: ... 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 USB board assembly removal 1 Remove the upper front cover 2 Disconnect the USB cable from the USB b...

Page 303: ...Connector locations and connections 5 1 5 Connector locations and connections Connections System board ...

Page 304: ... 3 Ground 4 LADJ2 5 VIDEO 0 CN 6 VIDEO 0 CN 7 Ground 8 5PHEAD 9 LPOW 10 Ground 11 LADJ CN 12 LPOW FB 13 LENA J3 Printhead HSYNC mirror motor 1 Ground 2 HSYNC C N 3 HSYNC I D 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 L ED ...

Page 305: ...10 Fuser DC 1 NARMEDIA 2 Ground 3 THERM 4 Ground 5 THUMP 6 5V dc 7 THUMPRET 8 EXIT SNS 9 3 3 V dc 10 I2C CLK L5 11 I2C DAT L5 J13 Operator panel 1 I2C DAT 2 5 V dc 3 I2C C LK 4 Ground 5 PANEL INT 6 3 3 V dc 7 Ground J14 Signature button 1 SM Cart 2 Ground System board see System board on page 5 1 Connector Pin no Signal ...

Page 306: ...heel sensor 11 5 V dc 12 TONER WHEELX 13 Ground J16 Ethernet port 1 2 3 4 5 6 7 8 9 10 11 12 13 J17 Parallel port J18 Front bottom options 1 Ground 2 24 V dc OTC OPT J20 Transport motor 1 BLDC_HALL 0 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 System board see System board on page 5 1 Connector Pin no Signal ...

Page 307: ...m front 1 Ground 2 24VPTCOPT J26 Paper size sensor autocomp motor 1 PSIZE2 2 Ground 3 PSIZE1 4 PSIZE3 5 Ground 6 TRAY1 POUT 7 TRAY1 PLOW 8 3 3V dc 9 ENCODER 10 5V dc J27 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 System board see System board on page 5 1 Connecto...

Page 308: ...out 1 MPF POUT 2 Ground 3 MPF L ED J29 Top options 1 RXD1R 2 Ground 3 TXD1BR 4 Ground J30 USB host back 1 2 3 4 5 6 7 USB host front connection 1 5 V USBICN 2 USB D I 3 USB D I 4 Ground 5 Ground Printhead fan 1 24V dc 2 PH FAN System board see System board on page 5 1 Connector Pin no Signal ...

Page 309: ...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 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 ...

Page 310: ...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 311: ...5 9 High voltage power supply Interconnect card Connector CN no Signal CN1 System board 1 Developer PWM 2 24 V dc R eturn 3 Charge PWM 4 24 V dc I N 5 TX PWM 6 TX Enable 7 TX CUR PWM 8 SVRO OUT Connector Connector Pin no Signal J1 1 J2 1 ...

Page 312: ...n 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 ...

Page 313: ... 3 prtrxd 4 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 ...

Page 314: ...din 2 Ground 3 prtrxd 4 Ground 5 Ground J2 Feed motor 1 fdmtr1 2 fdmtr2 3 Ground 4 Ground 5 tachft 6 5Vptt J3 Stepper motor 1 stpmtr 2 stpmtr 3 stpmtr 4 stpmtr 5 crtprsnt 6 stplow 7 stpphomo 8 Ground 9 5Vstpl 10 stprimed J4 Accessory connector 1 24 V dc 2 accmtr 3 Ground 4 Ground 5 tacha 6 5Vptt J5 Solenoid 1 Sol1 2 24 V dc J6 Stapler 1 Ground 2 pfrinstp 3 5Vsnsr2 ...

Page 315: ...Bin empty sensor 1 Ground 2 bnempty 3 5Vsnsr2 J10 Left side sensor board 1 Ground 2 full 3 NRFull 4 Ground J12 Pass thru sensor 1 Ground 2 psthruint 3 5Vptt J13 Cover open switch 1 5V dc 2 Ground 3 cvropin J14A 1 24V dc 2 Ground 3 5V i n J14B 1 prtxdout 2 Ground 3 prtrxd 4 Ground 5 Ground J15 Stapler door open 1 Dooropin 2 Ground 3 5Vswitch Connector Pin no Signal ...

Page 316: ...5 14 Service Manual ...

Page 317: ...e top cover and the power supply cover 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 maintain the print quality and reliability of the printe...

Page 318: ...6 2 Service Manual ...

Page 319: ...ber 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 Model information ...

Page 320: ...7 2 Service Manual Assembly 1 Covers 7 9 8 14 12 15 13 16 17 3 3 2 5 1 4 4 5 6 6 10 11 ...

Page 321: ...ring 1 Right hinge spring 1 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 13 40X0013 1 1 Clear LCD bezel 14 40X0235 1 1 Kit upper front panel button including Stop button 1 Menu button 1 Back button 1 LED cap 1 Navigation buttons 4 N...

Page 322: ...7 4 Service Manual Assembly 2 Frame 1 1 5 1 1 2 3 4 6 3 7 8 9 ...

Page 323: ... 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 40X0231 1 1 Left side hand holder 9 40X0285 1 1 Frame clip ...

Page 324: ...7 6 Service Manual Assembly 3 Frame 2 3 10 6 12 17 15 8 14 2 9 5 16 4 11 7 13 18 1 19 20 ...

Page 325: ...ng 9 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...

Page 326: ...7 8 Service Manual Assembly 4 Frame 3 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 1 3 6 7 6 11 3 6 ...

Page 327: ...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 328: ...7 10 Service Manual Assembly 5 Printhead 1 2 2 3 ...

Page 329: ...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 330: ...7 12 Service Manual Assembly 6 Paper feed autocompensator 5 3 4 6 2 1 7 1 6 ...

Page 331: ...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 40X4308 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 332: ...7 14 Service Manual Assembly 7 Paper feed multipurpose feeder 3 5 2 4 1 1 5 ...

Page 333: ...sembly 2 40X0310 1 1 Multipurpose feeder pick arm assembly with solenoid 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 1 Parts packet frame mounting screw PP 40X0165 NS Parts packet pick roll shaft clip PP 40X0165 ...

Page 334: ...7 16 Service Manual Assembly 8 Paper feed alignment 3 2 1 4 ...

Page 335: ... 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 336: ...7 18 Service Manual Assembly 9 Integrated 250 sheet paper tray 3 7 5 2 6 4 1 ...

Page 337: ...Units kit or pkg Description 9 1 40X3231 1 1 Integrated 250 sheet tray 2 40X0092 1 1 Side restraint 250 sheet tray 3 40X0093 4 1 Wear strips 4 40X0263 1 1 Pass thru plate 250 sheet tray 5 40X0094 1 1 Wear plate 250 sheet tray 6 40X0105 2 1 Restraint pad 7 40X0090 1 1 Back restraint 250 sheet tray ...

Page 338: ...7 20 Service Manual Assembly 10 Integrated 500 sheet paper tray 1 3 7 5 4 6 2 ...

Page 339: ...er Units mach Units kit or pkg Description 10 1 40X4663 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 340: ...7 22 Service Manual Assembly 11 Drives Main drive and developer drive 3 2 4 1 7 6 5 ...

Page 341: ... 1 1 Power takeoff shaft 500 sheet 200 210 400 410 3 40X0112 1 1 Power takeoff shaft spring 4 99A0954 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 342: ...7 24 Service Manual Assembly 12 Hot roll fuser Rear view Front view 6 10 1 2 3 4 7 11 12 14 9 5 8 8 6 13 9 ...

Page 343: ...666 1 1 Wax fuser wiper gray housing 5 40X0121 1 Fuser cover assembly kit including Thermistor 1 Thermostat 1 Left and right fuser lamp contact assemblies 1 6 Parts packet fuser mounting screw PP 40X0254 7 40X0239 1 Exit sensor flag spring kit including Spring 1 Flag 1 8 40X0236 1 1 Exit narrow media sensor cover 9 Parts packet PP 40X0165 10 40X0125 1 1 Exit sensor 11 40X0230 1 1 Exit sensor cable...

Page 344: ...7 26 Service Manual Assembly 13 Transfer charging 3 2 4 1 6 5 7 9 8 ...

Page 345: ...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 346: ...7 28 Service Manual Assembly 14 Electronics power supplies 3 5 2 4 1 ...

Page 347: ...ands 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 UK 2 40X4596 1 1 Power cord set 6 ft right angle Brazil 2 40X0301 1 1 Power co...

Page 348: ...7 30 Service Manual Assembly 15 Electronics card assemblies Note 1 2 3 4 5 5 ...

Page 349: ...X5923 1 1 System board assembly non network 000 3 40X5925 1 1 System board assembly non network 200 3 40X5927 1 1 System board assembly non network 400 4 40X5924 1 1 System board assembly network 010 4 40X5926 1 1 System board assembly network 210 4 40X5298 1 1 System board assembly network 410 5 40X3212 1 1 Bar code card assembly 5 40X3378 1 1 IPDS SCS card assembly 5 40X0199 1 1 PrintCryption ca...

Page 350: ...7 32 Service Manual Assembly 16 Electronics shields 5 6 2 1 3 4 7 2 4 2 2 2 2 ...

Page 351: ...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 010 210 410 6 40X0154 1 1 Inner shield assembly 1 slot 000 010 7 40X0222 1 1 Outer shield 1 slot 000 010 ...

Page 352: ...mbly 17 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 40X0264 1 1 Output bin sensor cable 1 3 2 ...

Page 353: ...ams 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 2 3 1 ...

Page 354: ...7 36 Service Manual Assembly 19 Cabling diagrams 3 3 5 2 4 1 ...

Page 355: ...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 HVPS 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 356: ...7 38 Service Manual Assembly 20 Cabling diagrams 4 3 4 2 1 ...

Page 357: ...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 358: ...7 40 Service Manual Assembly 21 Cabling diagrams 5 1 2 3 3 3 4 5 ...

Page 359: ...ption 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 5 40X0161 1 1 Ground cable ...

Page 360: ... Paper out arm 250 sheet 5 3 3 Parts packet screw auto comp mounting PP 99A0263 5 4 4 Parts packet PP 99A0263 6 40X3232 1 1 Pick arm assembly 7 56P1228 1 1 Bellcrank 250 sheet paper tray 8 99A1929 2 1 Bellcrank spring 250 sheet paper tray 9 40X4308 2 2 Pick roll assembly 10 40X3234 1 1 Bin low sensor with cable 11 40X3233 1 1 Option pass thru sensor 12 99A0272 1 1 Drive shaft 250 sheet 13 99A0275 ...

Page 361: ...it or pkg Description 23 1 40X3231 1 1 Tray assembly option 250 sheet 2 40X3235 1 1 Side restraint 250 sheet tray 3 56P1279 1 4 Wear strips 4 56P4230 1 1 Clip 250 sheet pass thru 5 99A0121 1 1 Plate 250 sheet tray wear 6 99A0120 1 2 Restraint pad 7 40X3236 1 1 Back restraint 250 sheet tray 3 7 5 2 6 1 4 ...

Page 362: ...1 1 Pick arm assembly 500 sheet 4 56P1228 1 1 Bellcrank spring arm 5 56P2540 1 1 Bellcrank spring 500 sheet option tray 6 40X4308 1 2 Pick roll assembly 7 40X3233 1 1 Option pass thru sensor 8 99A0275 1 1 Power takeoff spring 9 99A0447 1 1 Drive shaft 500 sheet 10 40X3234 1 1 Bin low sensor with cable 11 40X3247 1 1 Base assembly 500 sheet 12 56P4145 1 1 Paper out arm 500 sheet drawer 13 99A0063 1...

Page 363: ...ion Units kit or pkg Description 25 1 40X4663 1 1 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 56P4195 1 1 Plate 500 sheet wear 6 99A0120 1 2 Restraint pad 7 56P4147 1 1 Back restraint 500 sheet tray 1 3 7 4 6 2 5 ...

Page 364: ...7 46 Service Manual Assembly 26 Duplex option Asm Index Part number Units option Units kit or pkg Description 26 1 56P4100 1 1 Duplex assembly 250 sheet 1 56P4102 1 1 Duplex assembly 500 sheet 1 ...

Page 365: ...Parts catalog 7 47 Assembly 27 Envelope feeder Asm Index Part number Units option Units kit or pkg Description 27 1 40X3248 1 1 Complete envelope option 1 ...

Page 366: ...Units kit or pkg Description 28 1 40X3270 1 1 Complete output expander assembly 2 99A0104 1 1 Upper diverter spring 3 1 11 Parts packet PP 99A0263 4 56P4198 1 1 Output expander tray 5 56P4163 1 1 Left side cover 6 40X3265 1 1 Bin full dual sensor upper stacker assembly 3 5 2 1 3 3 3 6 4 ...

Page 367: ... expander 2 Asm Index Part number Units option Units kit or pkg Description 29 1 40X3267 1 1 Rear access door assembly 2 56P4235 1 1 Right side cover 3 Parts packet screw PP 99A0263 4 40X3264 1 1 Output expander pass thru sensor 3 2 4 1 3 ...

Page 368: ... Description 30 1 40X3263 1 Complete high capacity output expander 2 40X3267 2 1 Rear access door assembly 3 56P4211 4 1 Rear door latch 4 56P4204 1 1 Right cover 6 56P4205 1 1 Front cover 7 40X3268 1 1 Output tray assembly 8 56P4203 1 1 Left cover NS 56P4208 1 1 Tray sensing switch assembly 5 6 1 8 2 3 3 2 3 3 4 7 ...

Page 369: ...tion Units kit or pkg Description 31 1 99A0104 2 1 Upper diverter spring 2 99A0415 1 1 Swing arm spring 3 31 Parts packet PP 99A0263 4 56P4212 1 1 Bin full dual sensor upper stacker assembly flag 5 40X3265 1 1 Bin full dual sensor upper stacker assembly NS 56P4210 2 1 Output spring 3 5 2 4 1 3 ...

Page 370: ...7 52 Service Manual Assembly 32 High capacity output expander 3 1 ...

Page 371: ...Parts catalog 7 53 Assembly 32 High capacity output expander 3 Asm Index Part number Units option Units kit or pkg Description 32 1 40X3264 2 1 Stacker pass thru sensor ...

Page 372: ...7 54 Service Manual Assembly 33 5 bin mailbox 1 3 11 7 13 5 16 9 15 2 6 4 12 8 14 10 1 5 ...

Page 373: ...56P4211 2 2 Rear access door latch 6 99A0104 1 1 Upper diverter spring 7 56P4183 1 1 Rear access door 8 56P4178 1 1 Right side cover 9 40X3242 2 1 5 bin mailbox pass thru sensor 10 56P4182 5 1 Paper cap tray 11 56P4191 1 1 5 bin mailbox assembly kit 12 1 1 5 bin mailbox assembly kit order 56P4191 13 56P4186 5 1 Bin full flag 14 40X3240 5 1 Dual paper height sensor 15 Parts packet board mounting sc...

Page 374: ...7 56 Service Manual Assembly 34 5 bin mailbox 2 2 1 ...

Page 375: ...Parts catalog 7 57 Assembly 34 cont 5 bin mailbox 2 Asm Index Part number Units option Units kit or pkg Description 34 1 12 Parts packet board mounting screw PP 99A0263 2 40X2061 4 1 Diverter solenoid ...

Page 376: ...7 58 Service Manual Assembly 35 High capacity feeder 1 2 5 3 6 7 8 1 4 9 10 ...

Page 377: ...2 99A1818 1 1 Wear dimple strip 3 99A0681 4 1 Wear strip 4 40X3254 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 40X3252 1 1 2000 sheet option control card assembly 10 99A0658 2 2 Door magnet ...

Page 378: ...7 60 Service Manual Assembly 36 High capacity feeder 2 3 1 2 4 ...

Page 379: ...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 40X3262 1 1 AC external jumper cord 4 40X2669 1 1 Power supply board ...

Page 380: ...7 62 Service Manual Assembly 37 High capacity feeder 3 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 2 1 ...

Page 381: ... 4 Asm Index Part number Units option Units kit or pkg Description 38 1 3 Parts packet auto comp assembly mounting screw PP 99A0263 2 40X3255 1 1 Pick arm assembly 2000 sheet 3 40X4308 2 2 Pick roll assembly 4 40X3233 1 1 Option pass thru sensor 3 2 4 1 ...

Page 382: ...al Assembly 39 Kiosk vertical and horizontal paper adapters Asm Index Part number Units option Units kit or pkg Description 39 1 40X3280 1 Complete vertical kiosk option 2 40X3269 1 Complete horizontal kiosk option 2 1 ...

Page 383: ...40X3276 1 1 Rear access door 3 56P4211 2 1 Rear access door latch 4 56P4214 1 1 Right base assembly cover 5 56P4216 1 1 Stapler access cover 6 40X3274 1 1 Stapler access door switch assembly 7 40X3277 1 1 Output assembly tray 8 40X1816 1 1 Stacking bail kit 9 56P4213 1 1 Left base assembly cover 10 56P4218 1 1 Top assembly cover 3 7 5 9 2 10 6 4 8 1 3 ...

Page 384: ...7 66 Service Manual Assembly 41 StapleSmart finisher 2 Asm Index Part number Units option Units kit or pkg Description 41 1 40X3278 1 1 Stapler assembly 1 ...

Page 385: ...rts catalog 7 67 Assembly 42 StapleSmart finisher 3 Asm Index Part number Units option Units kit or pkg Description 42 1 40X3279 1 1 Switch assembly top cover open 2 99A0104 1 1 Spring upper diverter 2 1 ...

Page 386: ...7 68 Service Manual Assembly 43 StapleSmart finisher 4 Asm Index Part number Units option Units kit or pkg Description 43 1 99A2480 1 1 StapleSmart wheels maintenance kit 1 ...

Page 387: ...mbly NS 40X0171 1 1 Cartridge shipping package empty NS 40X1375 1 1 MarkNet 8000 Fast Ethernet NS 40X1376 1 1 MarkNet 8020 Gigabit Ethernet NS 40X1377 1 1 MarkNet 8030 Fiber Ethernet NS 40X1378 1 1 MarkNet 8050 wireless US NS 40X1562 1 1 MarkNet 8050 wireless non US NS 40X0291 1 1 Parallel 1284 B interface card NS 40X0290 1 1 RS232C serial interface card NS 40X4745 1 1 Universal adjustable tray as...

Page 388: ...7 70 Service Manual ...

Page 389: ...ON If you are installing options after setting up the printer turn the printer off and unplug the power cord before continuing Printer stand or printer base 2000 sheet drawer 250 sheet or 500 sheet drawer Duplex unit Printer CAUTION The printer requires two people to lift it safely For information on installing a printer stand printer base or 2000 sheet drawer see the instructions included with th...

Page 390: ...an to use the printer The tab A round peg B and square holes C on top of any drawer help you position the support unit so the edges are aligned properly Make sure the support unit is securely in place 3 Attach another optional drawer a duplex unit or the printer You can attach a label to the trays to indicate the tray number A B C ...

Page 391: ... tray and the 500 sheet duplex unit only works with printers that have a 500 sheet standard tray Make sure you have the appropriate duplex unit for the tray size installed in the printer 1 Place the duplex unit on top of any installed drawers or the table or printer cabinet where you plan to use the printer The tab A round peg B and square holes C on top of any drawer help you position the duplex ...

Page 392: ... the printer memory capacity and connectivity by adding optional cards The instructions in this section help you install any of the following options Memory cards Printer memory Flash memory Firmware cards Bar Code IPDS and SCS TNe PrintCryption Other options Printer hard disk RS 232 serial interface card Parallel 1284 C interface card MarkNet N8000 series internal print servers also called intern...

Page 393: ...sh memory a firmware card or an option card Note Use a Phillips screwdriver to remove the system board access cover 1 Push the release latch and lower the multipurpose feeder 2 Push the release latch and open the top front cover 3 Press both side door latches and open the side door 4 Loosen but do not remove the six screws A on the shield A ...

Page 394: ...5 Slide the shield to the right and then remove it 6 Set the shield aside Use the illustration to locate the connector for the card you want to install Firmware card connector Memory card connector Option card connectors ...

Page 395: ...l such as the printer frame before you touch a memory card 2 Push the latches away from the card on both ends of the memory card connector The memory card moves out of the connector as the latches open 3 Pull the memory card out of the connector Avoid touching the connection points along the edge of the card 4 Place the card into the original packaging If you do not have the original packaging wra...

Page 396: ...of the connector snap into place It may require some force to fully seat the card 6 Make sure each latch fits over the notch on the end of the card Removing or installing a flash memory or firmware card Removal 1 Remove the system board access cover See Accessing the printer system board on page A 5 Note If an option card has been installed you may need to remove the option card before removing th...

Page 397: ...on card before installing the flash memory or firmware card 2 Unpack the flash memory or firmware card 3 Holding the flash memory or firmware card A by the locking clips align the plastic pins on the card with the holes on the system board 4 Push the flash memory or firmware card firmly into place and release the locking clips The entire length of the connector B on the flash memory or firmware ca...

Page 398: ...ion card 1 Locate the card connectors on the system board 2 Remove the screw A and the cover plate B and save them If you are installing a tall card install it in connector 1 If you are installing two short cards on a model with multiple connectors use connector 1 first and then use connector 2 3 Unpack the card Save the packaging materials 4 Align the connection points on the card with the connec...

Page 399: ...inting and using features Canceling a print job There are several methods for canceling a print job Canceling a job from the printer operator panel See Canceling a job from the printer operator panel on page A 12 Canceling a job from a computer running Windows See Canceling a job from a computer running Windows on page A 12 Canceling a job from the taskbar Canceling a job from the desktop Cancelin...

Page 400: ...want to cancel 3 Press the Delete key on the keyboard Canceling a job from the desktop 1 Minimize all programs to reveal the desktop 2 Double click the My Computer icon Note If you do not have the My Computer icon you can access the printers folder by selecting Start Settings Control Panel and then go to step 4 3 Double click the Printers icon A list of available printers appears 4 Double click th...

Page 401: ...ngs Page and then press The printer returns to Ready after the page prints Printing a network setup page If the printer is attached to a network print a network setup page on the printer to verify the network connection This page also provides important information to configure the printer for network printing 1 Make sure the printer is on 2 Press on the operator panel 3 Press until Reports appear...

Page 402: ... stored in printer memory go to the printer and use the printer operator panel to specify what you want to do with your print job All confidential and held jobs have a user name associated with them To access confidential or held jobs you must first select the type of job confidential or held and then select your user name from the user name list Once you select your user name you can print all yo...

Page 403: ...he printer 1 Press until the appears next to Held jobs and then press 2 Press until the appears next to your user name and then press 3 Press until the appears next to Confidential jobs and then press 4 Enter your PIN For more information see Entering a personal identification number PIN on page A 15 5 Press until the appears next to the job you want to print and then press Note After your job pri...

Page 404: ...inter memory when the printer requires extra memory to process additional held jobs Windows 1 From a word processor spreadsheet browser or other application select File Print 2 Click Properties If there is no Properties button click Setup and then click Properties 3 Depending on the operating system you may have to click the Other Options tab and then click Print and Hold Note If you have difficul...

Page 405: ...inter automatically feeds print media from the next linked tray tray 4 By linking all trays standard and optional you effectively create a single source with a capacity of up to 4 100 sheets Make sure you load the same size and type of print media in each tray in order to link the trays Set the paper size and type for each tray to set the paper type or size 1 Press on the operator panel 2 Press un...

Page 406: ...ze Output bins Output bin name Each bin accommodates How many can be installed on the printer Bin is allowed to connect with Illustration of output bin Print media Printer Models Standard bin 250 sheets 75 g m2 of plain paper 150 transparencies 100 labels 25 envelopes 75 g m2 standard on the printer and located on top of the printer options in combinations as follows in this column Standard bin 50...

Page 407: ...her See the Setup Guide for information on how to install options in relation to each other Output bins continued Output bin name Each bin accommodates How many can be installed on the printer Bin is allowed to connect with Illustration of output bin Print media Printer Models 5210n 5310n mailbox 75 g m of plain paper expander or 5 bin 120 sheets 2 1 output high capacity mailbox 1 3 1 5 bin 5310n ...

Page 408: ...ues available to configure your output bins refer to the Menus and Messages Guide Note The bin sequence for linking always starts with the Standard Bin and proceeds from the Bin nearest to the floor to the Bin farthest from the floor To link output bins 1 Press on the operator panel 2 Press until the appears next to Paper Menu 3 Press 4 Press until the appears next to Bin Setup 5 Press 6 Press unt...

Page 409: ...bezel operator panel 4 15 blower duct 7 9 Button Test 3 7 buttons accessing service menus 3 1 Button Test 3 7 description function 2 2 operator panel button removal 4 68 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 canceling a print job 8 11 Card Stock Label Guide 1 9 card stock guidelines 1 19 cartridge duct remo...

Page 410: ...l wrap tests 3 8 serial wrap tests 3 9 INPUT TRAY TESTS Feed Test 3 13 Sensor Test 3 13 OUTPUT BIN TESTS Diverter Test 3 16 Feed Test 3 14 Feed to All Bins 3 14 Sensor Tests 3 15 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 Pa...

Page 411: ...parts catalog 7 28 removal 4 46 high capacity feeder locations 5 8 parts catalog 7 58 7 60 7 62 7 63 service check 2 96 high capacity output expander parts catalog 7 50 7 51 high capacity output stacker output sensor tests 3 16 service check 2 101 I inner paper deflector removal 4 48 inner shield parts catalog 7 32 removal 4 77 input sensor removal 4 49 input sensor tray tests 3 13 input source te...

Page 412: ...s 1 2 parts catalog 7 69 service checks 2 109 outer shield parts catalog 7 32 removal 4 69 output bin sensor tests 5 bin mailbox 3 16 high capacity output stacker 3 16 output expander 3 15 standard bin 3 15 output bins identifying A 18 output expander output sensor test 3 15 parts catalog 7 48 7 49 service check 2 111 output expander control board 5 11 P packaging 7 69 page count Fuser Page Count ...

Page 413: ... 4 74 service check 2 123 printing identifying output bins A 18 linking output bins A 20 Q quality pages 3 6 3 26 Quick Disk Test 3 18 Quick Test 3 5 3 9 R redrive assembly parts catalog 7 6 removal 4 75 redrive cap cover removal 4 6 redrive door 4 8 REGISTRATION 3 4 registration 3 4 relocation kit 7 69 removals bevel gear 4 22 cartridge duct 4 24 covers 4 5 fuser wiper cover assembly 4 5 laser co...

Page 414: ...ble 2 80 dead machine 2 80 duplex option 2 82 envelope feeder 2 84 fuser 2 87 fuser exit sensor 2 92 fuser narrow media sensor 2 93 fuser solenoid 2 95 high capacity feeder input tray 2 96 high capacity output stacker 2 101 input sensor 2 103 input tray optional 2 103 interconnect card 2 105 main drive 2 106 main fan 2 76 operator panel 2 107 options 2 109 output bin sensor 2 110 output expander 2...

Page 415: ... 78 service check 2 129 transparencies 1 17 tray linking A 17 U unique tools 1 20 unsatisfactory papers 1 16 upper front cover parts catalog 7 2 removal 4 12 upper front cover hinge assembly removal 4 79 upper front cover latch removal 4 14 upper paper deflector 4 80 user attendance messages 2 32 user line 2 link messages 2 43 user status displays 2 31 V verify print A 16 W warm up time 3 22 warni...

Page 416: ...I 8 Service Manual ...

Page 417: ...e 500 sheet output 40X0054 Main fan 500 sheet 40X0056 Redrive door assembly 250 sheet 000 010 40X0001 Fuser wiper cover assembly 7 3 2 117 3 8 40X0002 Redrive cap cover assembly 7 3 40X0004 Laser cover assembly 500 sheet output 200 210 400 410 7 3 7 3 40X0005 Paper support 7 3 7 3 7 39 40X0008 Right side cover 500 sheet output 200 210 400 410 7 3 40X0007 Right side cover 250 sheet output 000 01 7 ...

Page 418: ...200 210 400 410 40X0057 Output paper level flag 000 010 7 7 40X0058 Output paper level flag 200 210 400 410 7 7 7 5 40X0065 Frame extension nut plate 200 210 400 410 40X0059 Extension guide 7 7 40X0061 Laser cable assembly 7 11 40X0061 Laser printhead cable assembly 7 35 7 11 7 5 7 13 40X0068 Parts packet bellcrank assembly 250 sheet tray 000 010 7 13 40X0067 Pick arm assembly 250 sheet 000 010 7 ...

Page 419: ...or panel outer bezel with Dell logo 5310n 40X0151 USB board assembly 7 3 40X0152 Ethernet shield blank 010 210 410 7 33 7 33 40X0153 INA flat cover blank 7 33 7 41 40X0156 Bottom front autoconnect cable assembly 7 37 40X0157 Top autoconnect cable assembly 7 37 7 34 7 41 40X0162 System board to fuser board cable assembly 7 39 7 5 7 7 7 9 7 11 7 13 7 15 7 17 7 23 7 25 7 27 7 29 7 33 40X0163 Fuser AC...

Page 420: ...t door assembly 40X3255 Pick arm assembly 2000 sheet 40X0271 Power cord set Hong Kong 7 29 40X0272 Power cord set Japan 7 29 40X0280 Power cord set 6 ft straight Korea 7 29 7 29 40X0285 Frame clip 7 5 7 69 40X0290 RS232C serial interface card 7 69 7 29 40X0295 Power cord set Israel 7 29 40X0305 Power cord set Switzerland 7 29 7 29 40X0301 Power cord set AS NZ 7 29 7 29 40X0304 Power cord set Botsw...

Page 421: ... 40X3263 Complete high capacity output expander 7 50 40X3264 Stacker pass thru sensor 7 53 7 48 7 51 40X3267 Rear access door assembly 7 49 7 50 40X3268 Output tray assembly 7 50 7 64 7 48 40X3274 Stapler access door switch assembly 7 65 7 65 40X3276 Rear access door 7 65 40X3377 Forms card assembly 7 69 7 65 40X3278 Stapler assembly 7 66 7 64 40X3279 Switch assembly top cover open 7 67 40X3378 IP...

Page 422: ...0 7 29 56P4235 Right side cover 7 49 7375084 Relocation kit 250 250 sheet printer 7 69 7375085 Relocation kit 500 500 sheet printer 7 69 7 42 7 44 99A0104 Spring upper diverter 7 67 99A0104 Upper diverter spring 7 48 7 51 7 55 99A0121 Plate 250 sheet tray wear 7 43 7 43 7 45 99A0263 Parts packet board mounting screw 7 55 7 57 99A0263 Parts packet 7 42 7 48 7 51 7 63 99A0263 Parts packet auto comp ...

Page 423: ...b to the marks on one of the vertical lines The line that best matches the defects on the print job indicates which particular part may be causing the defect For example the distance between these two marks represents a repeating defect that occurs every 28 3 mm 1 11 in which means the charge rollers may need to be replaced 88 0 mm 3 46 in 51 7 mm 2 04 in Replace the charge rollers 28 3 mm 1 11 in...

Page 424: ... 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 5 4 3 ...

Page 425: ... sensor assembly toner sensor mounting screw Input sensor FRU GH686 PTR CBL IEEE 1284 LT PRL BLK PRINTER PRINTER ACCESSORIES CABLE IEEE 1284 LT PARALLEL BLACK CRU KJ447 CORD PWR 250V 10A 2 5M C13 ISR Power cord set 8ft Right Angle Israel CRU MG931 CORD PWR 250V 2 5M C13 UK Power cord set 8 ft right angle Arabic Austria Belgium Bluemark CIS Czechoslovakia Finland France Germany Greece Hungary Irela...

Page 426: ...er Nut 5 5mm Slim line open end wrench alignment assy mounting screw FRU HG358 PNL DLFTR INR SHEET 5210 5310 Inner Paper Deflector FRU HG362 ASSY FUSER W 115V LAMP Fuser assembly w 115 V lamp DAO w Screws FRU JG006 ASSY RLLR CHARGE 5210 5310 Charge Roll Arm Assembly FRU JG280 SNSR INPUT 5210 5310 Paper Input Sensor FRU JG281 LEVER LNK GEAR REL 5210 5310 Gear Link Lever FRU JG283 ASSY RLLR CHR DUAL...

Page 427: ...er FRU JG456 CVR LAMINATED LF OTR 5210 5310 Left Cover Assy Inner and Outer Screw FRU YF748 ASSY HNG CVR FRT UPR Upper Front Cover Hinge Assy includes counter balance spring Upper front cover hinge Op panel cable cover open switch cable left right cable cover left right hinge spring FRU Power Source DG920 PWR SPLY LVPS 220V 5210 LVPS220 V EMEA for Sherry 5210n FRU GG648 PWR SPLY HVPS 5210 310 High...

Page 428: ...ASSEMBLY Base SERVICE KIT PRINTER PRINTER ACCESSORIES 110V 5310N CRU Cables and Cords CH617 ASSY CBL CON FUSER 5210 5310 Fuser Connector Cable assembly FRU DG918 ASSY CBL BD FUSER SYS 5210 310 Cable Fuser System Bd Sherry Chablis FRU DH482 ASSY CBL FUSER LVPS 5210 5310 AC Lamp fuser to LVPS Cable assembly FRU GG024 PWR SPLY HVPS W SNSRS 5210 310 Cable Assembly for HVPS includes cable assembly tone...

Page 429: ... GG653 SNSR EXIT 5210 5310 Fuser Exit Sensor w cable FRU GG654 ASSY RLLR TRANSFER 5210 5310 Transfer Roller only w tech sheet FRU GG658 ASSY CBL SNSR MPF 5210 5310 MPF sensor w cable FRU HG009 FDR ASSY ALIGN PAPER W TOOL Paper Alignment Assembly Includes Paper Feed alignment assy Screw Ref Ground Clip Washer Nut 5 5mm Slim line open end wrench alignment assy mounting screw FRU HG358 PNL DLFTR INR ...

Page 430: ... w 5 laser cover mounting screws FRU JG282 PNL GEAR DRV MN GRD PLSTC Main Drive Gear Plastic Gard w screw FRU JG428 CVR FEEDER ENVELOPE 5210 5310 Envlope Feeder Port Cover CRU JG456 CVR LAMINATED LF OTR 5210 5310 Left Cover Assy Inner and Outer Screw FRU YF748 ASSY HNG CVR FRT UPR Upper Front Cover Hinge Assy includes counter balance spring Upper front cover hinge Op panel cable cover open switch ...

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