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Lexmark X925 7541-03 series, Service Manual

The Lexmark X925 7541-03 series is a high-performance printer designed to meet all your business needs. With our Service Manual, you can easily troubleshoot any issues and perform maintenance tasks hassle-free. Download this invaluable manual for free at manualshive.com and ensure the optimal performance of your Lexmark printer.

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viii

  Service Manual 

7541-03x

Engine Setting 

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

Model Name  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Configuration ID  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Cal Ref Adj  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Par 1 Strobe Adj  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

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

Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Print Log  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Clear Log  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

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

Scanner Calibration Reset  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
ASIC Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Feed Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Sensor Test   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
ADF Magnification   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

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

Theory of operation

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

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

Electrophotographic Process (EP Process)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
MFP electrophotographic process basics   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Step 1: Charge  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
Step 2: Expose  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31
Step 3: Develop  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Step 4a: First transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Step 4b: Second transfer  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Step 5: Fuse  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Step 6: Clean/Erase  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

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

Paper feed  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Feeding paper from a tray   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-40
Feeding paper from the MPF  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

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

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

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

What is RGB color?  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
What is CMYK color?  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
How is color specified in a document to be printed?   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
How does the printer know what color to print?  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Should I use PostScript or PCL emulation? What settings produce the best color?   . . . . . . . . . 3-47
Why doesn't the printed color match the color I see on the computer screen?  . . . . . . . . . . . . . 3-47
The printed page appears tinted. Can I adjust the color?   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
My color transparencies seem dark when they are projected. Is there anything I can do to improve the 
color?  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
What is manual color correction?  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
How can I match a particular color (such as a corporate logo)?   . . . . . . . . . . . . . . . . . . . . . . . . 3-48
What are detailed Color Samples and how do I access them?  . . . . . . . . . . . . . . . . . . . . . . . . .3-49

Repair information

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   

4-1

Handling ESD-sensitive parts

 

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

Flatbed / ICC card NVRAM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
RIP board/operator panel replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Printhead controller board / engine board replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

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

Removal procedures

 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

Cover Removals

 

 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

RIP cover  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Scanner power supply access cover   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Summary of Contents for X925 7541-03 series

Page 1: ...of contents Start diagnostics Safety and notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Revised November 14 2014 ...

Page 2: ...eferences in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intelle...

Page 3: ... sizes supported by the printer 1 6 Media types 1 7 Media weights 1 8 Media guidelines 1 9 Paper 1 9 Paper characteristics 1 9 Unacceptable paper 1 10 Selecting paper 1 10 Scan fax and copy specifications 1 11 General specifications 1 11 Fax features 1 12 Scanner specifications 1 13 MFP scan speed 1 14 Tools required for service 1 15 Acronyms 1 16 Diagnostic information 2 1 Start 2 1 Safety featur...

Page 4: ...nd resolving scanner jams 2 29 280 06 Paper missing 2 29 283 01 Scanner static jam Scan sensor jam 2 30 283 05 Scan sensor jam 2 31 285 05 Scanner ADF eject jam 2 32 290 11 Scanner ADF cover open jam 2 33 291 06 Flatbed cover open 2 35 292 01 Scanner carriage locked 2 35 ADF paper jam service check 2 36 Error codes 2 38 149 01 Abnormal exit motor 2 38 941 05 Abnormal EEPROM 2 39 950 xx Service NCV...

Page 5: ...ting 2 56 841 02 Delayed interrupt detected 2 57 841 03 Failed indirect register test 2 57 841 04 Failed external DRAM test 2 57 841 05 Image pipe time out 2 57 841 06 Scanner did not initiate scan 2 58 842 00 No response 842 01 HW protocol 842 02 Logical protocol 2 58 843 00 Carriage Home 2 59 843 03 Pick roll failed to engage 2 59 844 00 Lamp failure Front side 2 60 849 01 Device had modem insta...

Page 6: ...port 2 94 Flash options 2 94 DRAM options 2 94 Hard disk option 2 95 Network card option 2 95 Error code 976 Network card x 2 95 54 Network x Software error 2 95 Power supply Dead machine service check 2 96 Printhead service check 2 97 Transfer belt up down check 2 97 Unable to print from USB thumb drive service check 2 98 Waste toner bottle missing service check 2 98 Wrong paper size service chec...

Page 7: ...ings 3 15 Font Sharpening 3 15 Require Standby 3 15 UI Automation 3 15 Key Repeat Initial Delay 3 16 Key Repeat Rate 3 16 Clear Custom Status 3 16 USB Speed 3 17 USB PnP 3 17 Automatically Display Error Screens 3 17 Exit Config Menu 3 17 Diagnostics mode 3 18 Entering Diagnostics mode 3 18 Diagnostic mode menus 3 18 SCANNER CALIBRATION 3 20 Adjust Calibration Values 3 20 Reset Calibration Values 3...

Page 8: ...hat is RGB color 3 47 What is CMYK color 3 47 How is color specified in a document to be printed 3 47 How does the printer know what color to print 3 47 Should I use PostScript or PCL emulation What settings produce the best color 3 47 Why doesn t the printed color match the color I see on the computer screen 3 47 The printed page appears tinted Can I adjust the color 3 47 My color transparencies ...

Page 9: ...ck removal 4 43 Cassette stopper removal 4 44 Left side removals 4 45 Left EMI shield removal not a FRU 4 45 Low volt power supply removal 4 51 Main fan removal 4 53 Power supply fan removal 4 55 Theta sensor removal 4 56 Density sensor removal 4 57 Main switch 4 58 Scanner power supply removal 4 58 Right side removals 4 61 Fuser removal 4 61 Handle cover removal 4 62 Duplex removal 4 63 Paper fee...

Page 10: ...utch 4 132 ADF input tray 4 133 ADF main feeder 4 134 ADF clutch 4 137 ADF hinge 4 137 FB hinge 4 138 Tray paper size sensors 4 138 ADF cover open ADF pick sensor 4 142 ADF cover open sensor actuator 4 143 Paper present paper in sensor 4 144 Paper present sensor actuator 4 145 Paper in sensor actuator 4 145 Paper path sensor 4 146 Scan sensor 4 146 Scan sensor actuator 4 148 Scan sensor cover not ...

Page 11: ... 203 Paper size switches removal 4 203 Paper level sensor removal 4 204 Transport sensor removal 4 204 Paper empty sensor removal 4 205 Paper full sensor removal 4 205 Option controller board removal 4 206 Stepper motor removal 4 206 Tray lift motor removal 4 207 Option door inter lock switch removal 4 208 Paper feed clutch removal 4 209 Adjustments 4 211 Calibrating the scanner 4 211 Calibrating ...

Page 12: ...e 2 7 20 Assembly 11 Base 3 7 22 Assembly 12 Paper feed 7 24 Assembly 13 Electrical 1 7 26 Assembly 14 Electrical 2 7 28 Assembly 15 Upper assembly 7 30 Assembly 16 Printhead controller board cables 7 32 Assembly 17 Paper trays 7 34 Assembly 18 Fuser 7 36 Assembly 19 550 sheet option feeder covers 7 38 Assembly 20 550 sheet option feeder base 7 40 Assembly 21 550 sheet option feeder paper feed 7 4...

Page 13: ...Notices and safety information xiii 7541 03x Go Back Previous Next Notices and safety information This device is an LED based printer ...

Page 14: ...xiv Service Manual 7541 03x Go Back Previous Next ...

Page 15: ...es Les consignes d entretien et de réparation de ce produit s adressent uniquement à un personnel de maintenance qualifié Le démontage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laquelle v...

Page 16: ...rmación sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltaje de la parte del equipo c...

Page 17: ...t d aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual esteu...

Page 18: ... problems 4 Repair information provides instructions for making printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual...

Page 19: ...er Belt Counter 2013 07 01 Added Steps before starting the 9yy xx service checks 2012 01 07 Added connector information for CN19 and CN20 under Printhead controller connectors on page 5 10 2012 10 23 Updated Imaging unit photo developer missing service check Step 5 and 6 Changed sub unit to subframe 2012 06 25 Added Safety feature notice on page 2 1 Updated and changed the Abnormal fuser temperatu...

Page 20: ...tatements CAUTION A caution identifies something that might cause a servicer harm CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION This type of caution indicates a hot surface CAUTION This type of c...

Page 21: ...rallel ports The printer also has flexible paper handling It supports a wide variety of paper sizes and has a standard multipurpose feeder that makes it easy to print on envelopes transparencies labels card stock and non standard size paper You can add optional inputs to the base printer which can increase the printer paper capacity to 2100 sheets Maintenance approach The diagnostic information in...

Page 22: ...rinter supports up to three 550 sheet trays CAUTION TIPPING HAZARD Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a high capacity input tray a duplex unit and an input option or more than one input option If you purchased a multifunction printer MFP that scans copies and faxes you may need additional furn...

Page 23: ... following options are not available in every country or region Available internal options Memory cards Printer memory Flash memory Fonts Firmware cards Bar Code PrintCryptionTM Printer hard disk LexmarkTM Internal Solutions Ports ISP RS 232 C Serial ISP Parallel 1284 B ISP MarkNetTM N8250 802 11 b g n Wireless ISP MarkNet N8130 10 100 Fiber ISP MarkNet N8120 10 100 1000 Ethernet ISP Media handlin...

Page 24: ... at 50 to 60 hertz Hz nominal 90 to 137 V ac extreme High voltage models 220 to 240 V ac at 50 to 60 hertz Hz nominal not available in all countries and regions Clearances Printing states Power Off 0W Sleep Mode 11W Hibernate Mode 3W Ready Mode 105W Continuous printing 620W 1 Right 385 mm 15 16 in 2 Front 609 6 mm 24 in 3 Left 100 mm 3 94 in 4 Rear 100 mm 3 94 in 5 Top 285 mm 11 22 in Allow additi...

Page 25: ...546 ft 0 to 2300 meters Atmospheric pressure 74 6 kPa Ambient operating environment Temperature 15 6 to 32 20 C 60 to 900 F Relative humidity 8 to 80 Storage and shipping packaged printer with or without print cartridge Temperature 40 to 110 F 40 to 43 3 C In some cases performance specifications such as paper OCF EP cartridge usage are measured at an ambient condition Status 1 meter average sound...

Page 26: ...e When Vinyl Label is selected print speed is 35ppm Note When using custom size media it is critical that the user define the actual width via the Paper Menu Universal Setup on the op panel for best reliability Processor 1 GHZ IBM Power PC processor Memory Standard memory 512 mb Optional memory 256 512 and 1024 MB 1 200 pin x 64 DDR 2 SO DIMMs 1 slot Optional flash 256 mb Paper specifications Pape...

Page 27: ... mm 7 3 x 10 5 in Oficio 216 x340 mm 8 5 x 13 4 in Folio 216 x 330 mm 8 5 x 13 in Statement1 140 x 216 mm 5 5 x8 5 in Tabloid Universal Plain Paper 64 to 297mm x 148 to 432mm Banner 210 to 297mm x 433 to 12129mm 140 x 210 mm 5 5 x 8 3 in up to 216 x 356 mm 8 5 x 14 in 210 to 297mm x 148 to432 mm 7 3 4 Envelopes Monarch 3 98 x 191 mm 3 9 x 7 5 in 9 Envelope3 98 x 226 mm 3 9 x 8 9 in 10 Envelope3 10...

Page 28: ...b 75g m2 to 128g m2 Short Grain 28lb to 34lb 105g m2 to 128g m2 Card Stock max Cover 50lb 42lb 135g m2 157g m2 Index 67lb 75lb 120g m2 157g m2 Tag 74lb 85lb 120g m2 157g m2 MFS MPF Duplexer All sizes supported by engine Xerographic and Bond Long Grain 16lb to 34lb 60g m2 to 128g m2 Short Grain 16lb to 34lb 60g m2 to 128g m2 Recycled Long Grain 20lb to 34lb 75g m2 to 128g m2 Short Grain 28lb to 34l...

Page 29: ...er characteristics The following paper characteristics affect print quality and reliability Consider these characteristics when evaluating new paper stock For detailed information see the Card Stock Label Guide available on the Lexmark Web site at http support lexmark com Weight The printer can automatically feed paper weights from 60 to 220 g m2 16 to 58 lb bond grain long Paper lighter than 60 g...

Page 30: ...bers such as cotton possesses characteristics that can result in degraded paper handling Unacceptable paper The following papers are not recommended for use with the printer Chemically treated papers used to make copies without carbon paper also known as carbonless papers carbonless copy paper CCP or no carbon required NCR paper Preprinted papers with chemicals that may contaminate the printer Pre...

Page 31: ... DRAMM DIMM slots 1 Wireless option Yes ISP INA slots 1 DLE Firmware card font card and flash memory card slots 2 The following combinations are supported when you use more than one slot DLE and user flash DLE and font card Font and User flash Paper handling Paper input standard 250 and 150 sheet tray 50 MPF Optional paper handling Input 550 sheet tray up to 3 Optional paper handling Output None D...

Page 32: ...for both Send and Receive Delayed send Supported Block junk fax banned fax list Based on Caller ID or Remote Station ID Fax shortcuts Average shortcut includes 25 characters for name 10 characters for number and four characters for shortcut ID Shortcuts can contain one phone number or multiple numbers Each number is a location see the Preferences area for the maximum number of locations xxx Broadc...

Page 33: ...scanner ADF type Re circulating Dual Pass Automatic Document Feeder RADF Scanner ADF document input and output capacity 100 sheets 20 lb 75 g m2 bond Scanner media depth thickness Maximum 0 11mm Minimum 0 08 mm Scanner media weight Maximum 32 lb 120 g m2 Minimum 16 lb 60 g m2 Document size Maximum 11 8 x 25 in 299 72 x 635 mm Short Edge Feed SEF Minimum 4 x 5 04 in 101 6 x 128 02 mm SEF Document s...

Page 34: ... 03x Go Back Previous Next MFP scan speed Note Scan performance is measured as 150 dpi 1 bit for mono and 150 depi 24 bit for color Media size Simplex Duplex Mono Color Mono Color Letter plain 32 32 13 13 A4 plain 33 33 14 14 ...

Page 35: ... magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade 7 32 inch 5 5 mm open end wrench 7 0 mm nut driver Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 Flashlight optional ...

Page 36: ...haracter set dc Direct Current DIMM Dual Inline Memory Module DLE Downloadable emulator DRAM Dynamic random access memory DVM Digital multimeter ECC Error correcting code ECM Error correction mode EDO Enhanced Data Out EEPROM Electrical Erasable Programmable Read Only Memory ENA External Network Adapter EOL End of life EP Electrophotographic process EPROM Erasable programmable read only memory ESD...

Page 37: ...Operator correctable failure OCR Oil coating roll OEM Original Equipment Manufacturer OHP Overhead projector OPC Optical photo conductor OPT Optical Sensor PC Photoconductor PDF Portable Document Format PICS Problem isolation charts PIN Personal identification number PIXEL Picture element PJL Printer Job Language POR Power on reset POST Power on self test PPDS Personal Printer Data Stream ppm Page...

Page 38: ...Toner Add Roll TPS Toner Patch Sensing TTM Tandem Tray Module TVOC Total Volatile Organic Compound UAT Universally Adjustable Tray UPR Used Parts Return USB Universal Serial Bus V Volts V ac Volts alternating current V dc Volts direct current VOM Volt Ohmmeter VTB Vacuum Transport Belt XPS XML Paper Specification Y Yellow ...

Page 39: ...er will automatically shutdown When the printer shuts down the on off power switch will physically move to the off position For more information on how to diagnose and service this event see ON OFF switch automatically switching to the Off position service check on page 2 48 Error code or symptom Location Print quality issues Go to Print quality issues on page 2 4 Scanner image issues Go to ADF sc...

Page 40: ...umidifiers cold spaces near open flames and dusty areas Avoid sites exposed to direct sunlight Print paper checks Use the recommended paper for this printer Paper dampness Make a trial print with paper from a newly opened package and check the result To determine the corrective action necessary to repair a printer look for the following information Does the POR stop Check the POR Power On Reset se...

Page 41: ...e is an error power on is halted Fuser thermistor checked if there is an error power on is halted 5 LED illuminates 6 RIP initialized ROM is checked if there is an error power on is halted Memory checked if there is an error power on is halted 7 Main tray lift motor moves paper up to position 8 Printer condition checked Check for jams if there is an error power on is halted Query the toner cartrid...

Page 42: ...e transfer module transfer belt and transfer roll for damage Replace if damaged 4 Inspect the imaging units and toner cartridges for damage Replace if damaged 5 If paper other than 20lb plain letter A4 paper is being used load 20lb plain letter A4 and print the Print Quality pages to see if the problem remains 6 Use Tray 1 to test print quality problems 7 Print the Print Quality Pages and then loo...

Page 43: ...onnect the ribbon cable on both ends 4 Replace the LED printhead Did this fix the problem Problem resolved Go to step 5 5 Are the contacts on the HVPS clean Go to step Clean the contacts on the HVPS 6 Are the spring contacts on the sub frame damaged Replace the subframe Go to step 7 7 Replace the HVPS Did this fix the problem Problem resolved Contact your second level support Step Action and quest...

Page 44: ...e drum of the imaging unit Replace the imaging unit Go to step 2 2 Is there dirt on the exposing surface of the LED printhead Go to step 3 Go to step 4 3 Clean the LED printhead Did this fix the issue Problem resolved Go to step 4 4 Replace the defective LED printhead Did this fix the issue Problem resolved Contact your second level support Step Action and questions Yes No 1 Check the condition of...

Page 45: ...e transfer belt Clean the roll if needed Note Be careful when cleaning the dirt of the transfer roll Be careful to not deform the roll Replace the transfer roll if it is scratched 3 Imaging unit Check for scratches of unevenness on the photoconductor drum Replace the imaging unit if the drum is damaged Look for dirt on the rolls Replace the imaging unit if the rolls are dirty Step Action and quest...

Page 46: ... Problem resolved Go to step 6 6 Check the transfer roll for dents Are there any dents in the transfer roll Replace the transfer roll Go to step 7 7 Remove the transfer belt and check the surface for waviness or other irregularities Are the surface irregularities Replace the transfer belt Contact your second level support Step Action and questions Yes No 1 Check the drum on the imaging unit for ov...

Page 47: ... 2 2 Check for dewing or moisture on the LED printheads Is there moisture on the printheads Let the printheads dry Move the printer to a less humid location if needed Go to step 3 3 Using the Administrative menu move the transfer belt to the up and down position Does the belt move Go to step 4 Replace the belt 4 Check the transfer roll for proper installation Is the transfer roll installed correct...

Page 48: ...Check the registration rolls for dirt or debris Is there dirt on the registration rolls Clean the registration rolls with a lint free cloth Step Action and questions Yes No 1 Check the fuser for proper installation Is the fuser properly installed Go to step 2 Reinstall the fuser 2 Check connection CN on the LVPS for proper connection Is the cable properly connected Go to step Go to step 3 Check CN...

Page 49: ...rting check the media route for foreign objects such as staples clips and scraps in the media path Step Check Yes No 1 Check the large and small platen glass on the scanner unit assembly Is the large and small platen glass contaminated Clean both sides of the large and small platen glass Go to step 2 2 Check the three mirrors in the scanner unit assembly Are the three mirrors contaminated or show ...

Page 50: ...o to step 4 4 Perform a print test using the scanner unit assembly Does the error continue Replace the scanner unit assembly Go to Flatbed assembly removal on page 4 116 Problem solved 5 Perform a print test using the ADF unit assembly Does the error continue Replace the ICC board Go to ICC board on page 4 123 Problem solved Step Check Yes No 1 Check the large platen glass on the scanner unit asse...

Page 51: ... scanner CCD assembly Does the error continue Replace the scanner CCD assembly Go to CCD chassis on page 4 124 Problem solved 5 Perform a print test using the flatbed scanner assembly Does the error continue Replace the ICC board Go to ICC board on page 4 123 Problem solved Step Check Yes No ...

Page 52: ...Go to step 3 Problem solved 3 Check for obstructions in the area of the media feed path in the ADF Is the media feed path free from any obstructions Go to step 4 Remove obstructions 4 Is the ADF left cover assembly properly and evenly closed Go to step 5 Open then properly close the ADF left cover assembly 5 Check the ADF pick roll assembly for damage and wear Is the ADF feed pick roll assembly fr...

Page 53: ...Go to step 4 Open then properly close the ADF left cover assembly 4 Check the ADF pick roll assembly for damage and wear Is the ADF feed pick roll assembly free from damage and wear Go to step 5 Replace the ADF feed pick roll assembly Go to ADF pick roll removal on page 4 114 5 Check the ADF separator roll Is the separator roll free from damage and wear Go to step 6 Replace the separator roll Go t...

Page 54: ...he ribbon cables to the ICC board and CCD Did this fix the problem Problem resolved Go to step 5 4 Check the cables for continuity Is there continuity Go to step 6 Go to step 5 5 Replace the ribbon cables from the ICC board to the CCD Did this fix the problem Problem resolved Go to step 6 6 Replace the ICC Did this fix the problem Problem resolved Go to step 7 7 Replace the CCD Did this fix the pr...

Page 55: ...05 Scanner ADF Eject Jam 2 200 xx Paper jam in the transfer carry area 3 250 Paper jam in the MPF tray 4 201 xx Paper jam in the fuser entry area 230 Paper jam in the duplex 231 39 Paper jam in the duplex Check the duplex sensor area at the bottom of the duplex 5 24x Paper jam in the papertray x indicates which tray the jam is in 6 203 Paper jam at the paper exit area 7 292 01 Scanner Carriage Loc...

Page 56: ...age is in the fuser the fuser nip release lever should be lowered After removing the jammed page return the lever to the proper position 3 Close the right side cover 4 Press Continue jam cleared 201 paper jam 1 Open the right side cover 2 Determine where the jam is located and remove it a If the paper is visible under the fuser grasp it on each side and pull it out b If the paper is not visible re...

Page 57: ... jam cleared 203 paper jam 1 Grasp any jammed paper that is visible in the exit bin and gently pull it out Note Make sure all paper fragments are removed If the page is in the fuser the fuser nip release lever should be lowered After removing the jammed page return the lever to the proper position 2 Press Continue jam cleared ...

Page 58: ...1 03x Go Back Previous Next 230 paper jam 1 Open the right cover 2 Lift the duplexing unit mechanism away from the cover 3 Remove any jammed paper 4 Lower the mechanism 5 Close the right cover 6 Press Continue jam cleared 1 2 ...

Page 59: ...541 03x Go Back Previous Next 231 39 paper jam 1 Open the right cover 2 Lift the duplexing unit mechanism away from the cover 3 Remove any jammed paper 4 Lower the mechanism 5 Close the right cover 6 Press Continue jam cleared 1 2 ...

Page 60: ...the right cover and pull any jammed pages out 2 Open Tray 1 ad pull the jammed pages up and out 3 Close Tray 1 4 Press Continue jam cleared Jam in the optional trays 1 Open the side affected tray s access door and remove the jammed pages Note Make sure all paper fragments are removed 1 2 ...

Page 61: ...vious Next 2 Open the affected tray and remove the jammed pages 3 Close the tray 4 Press Continue jam cleared 250 paper jam 1 Remove the jammed pages from the multipurpose feeder 2 Load paper into the multipurpose feeder 3 Press Continue jam cleared ...

Page 62: ...er over The curling could be due to humidity conditions 2 Paper feed unit rollers Roller clutch Are the rollers dirty or worn Replace as needed If there is a failure to pick and the feed rollers are clean check the roller clutch on the paperfeed unit This check can be performed by turning the paper feed roll in both directions If the shaft can be turned in both directions replace the roller clutch...

Page 63: ...e the registration sensor If this doesn t fix the problem replace the engine board FRU Action 1 Transfer belt unit Rear paper guide Discharge brush Fuser Remove any buildup of toner Replace any damaged or worn parts Check the paper exit flag on the fuser for damage Replace the fuser if necessary 2 Fuser entry sensor Check the fuser entry sensor to ensure it is in it s position and not dislodged Ch...

Page 64: ...ex clutch Be sure the clutch turns freely with no binding and it is properly installed Check for wear or damage to the associated gears Replace as necessary 4 Feed roller solenoid assembly Paper re feed solenoid assembly Check for proper operation of the solenoid and linkage Replace as necessary 5 Paper tray Check to see if the paper edge guides have shifted If so re time by removing the screw and...

Page 65: ...gine board 2 Paper out sensor Paper feed unit Paper level sensor Turn the printer on and open the right cover and duplex Bypass the right cover door open interlock switch With the paper tray empty and the paper out sensor blocked pull out and replace the cassette If the tray rises and stays in place check for a dirty paper out sensor and inspect the paper empty sensor actuator on the paper feed un...

Page 66: ...g the registration clutch and the problem remains replace the printer controller board FRU Action 1 MPF tray paper guides Check the guides to ensure they are not binding Also check the guides to ensure they are correctly adjusted for the paper in the tray 2 MPF roll cover Make sure the MPF roll cover is properly installed and not obstructing the paperpath Check for broken tabs and replace the cove...

Page 67: ...sensor dislodged Go to step 7 Go to step 8 7 Properly install the sensor Did this fix the problem Problem resolved Go to step 8 8 Check the sensor ADF paper present for proper operation 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor ADF paper present Does the display on the operator panel change every time the sensing area of the above sensor is i...

Page 68: ...h Sensor Tests 4 Observe the line sensor ADF Skew and Scan sensor Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 6 Go to step 9 6 Check the connections along the cable from the sensor to J1 on the ADF relay card Are all the connections properly connected Go to step 8 Go to step 7 7 Properly connect the connectors D...

Page 69: ...ly connected to the ADF relay card Go to step 7 Go to step 6 6 Reconnect the cable to the ADF relay card Did this fix the issue Problem resolved Go to step 7 7 Check pin 1 4 7 10 for 5V and pin 3 6 9 12 for GND on connector J1 on the ADF relay card Are they present Go to step 8 Go to step 9 8 Replace the inner cover sensor assembly Did this fix the issue Problem resolved Go to step 9 9 Check the A...

Page 70: ...u 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor ADF exit sensor Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 10 Go to step 9 9 Check J4 on the ADF relay card for proper connectivity Is the sensor cable properly connected to the ADF relay card Go to step11 Go to step 10 10 Reconnect the cabl...

Page 71: ...ANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor Cover open Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 10 Go to step 9 9 Check the sensor connection for proper connection to CN1 on the ADF relay and the paper present sensor Is the cable properly connected Go to step 11 Go to step 10 10 Connect the cab...

Page 72: ...34 Service Manual 7541 03x Go Back Previous Next 18 Replace the ICC board Did this fix the issue Problem resolved Replace the RIP board See RIP board removal on page 4 73 Step Action and questions Yes No ...

Page 73: ... Go to step 3 3 Check all the connections from the FB cover open sensor to J1 on the ICC board Are they properly connected Go to step 5 Go to step 4 4 Properly connect the connections Did this fix the problem Problem resolved Go to step 5 5 Replace the sensor Did this fix the problem Problem solved Go to step 6 6 Check the cable connections from the ICC board to the RIP Are the cables properly con...

Page 74: ... sensor ADF paper present Are the sensors working properly Go to step 6 Go to step 9 6 Check the leading edge of the paper to ensure the paper is not curled or bent in a way that would keep it from contacting the paper present sensor actuator Is the paper damaged Bad media Replace the media Go to step 7 7 Check for dirt in the ADF scan sensor paper in sensor and paper pass sensor See Flatbed ADF s...

Page 75: ...nostic information 2 37 7541 03x Go Back Previous Next 16 Replace the ICC board Did this fix the issue Problem resolved Replace the RIP board See RIP board removal on page 4 73 Step Questions actions Yes No ...

Page 76: ...01 Tray 1 error See 146 01 Tray1error on page 2 52 146 03 Tray 3 error See 146 03 Tray 3 error on page 2 52 146 04 Tray 4 error See 146 04 Tray 4 error on page 2 53 146 05 Tray 5 error See 146 05 Tray 5 error on page 2 54 121 04 Abnormal belt thermistor See 121 04 Belt thermistor error on page 2 47 113 01 HDCONT M HEAD error See 113 01 Magenta printhead error on page 2 45 112 01 HDCONT C HEAD erro...

Page 77: ...el at the same time without a POR in between See 950 00 950 29 EPROM mismatch failure on page 2 68 952 xx Service NV Failure Perform a POR to clear the error 953 xx Service NVRAM Failure Replace the RIP board Replace the ICC PCBA if replacing the RIP board does not fix the problem 954 xx Service NVRAM Failure 955 00 Service Code CRC loc 956 xx Service System Board 957 xx Service System Board 958 x...

Page 78: ...AM test on page 2 57 841 05 Image pipe timeout See 841 05 Image pipe time out on page 2 57 841 06 Scanner did not initiate scan See 841 06 Scanner did not initiate scan on page 2 58 842 00 No response See 842 00 No response 842 01 HW protocol 842 02 Logical protocol on page 2 58 842 01 HW Protocol See 842 00 No response 842 01 HW protocol 842 02 Logical protocol on page 2 58 842 02 Logical protoco...

Page 79: ...ality Adjust Receive Threshold 7XX Error occurred when sending a frame Check line quality Adjust Transmit Level Select a lower Max Speed value under Fax Send settings 800 Received EOT unexpectedly from the modem in V34 mode If error persists disable V34 modulation scheme 802 Too many timeouts occurred during ECM reception If error persists disable ECM mode 803 Fax cancelled by user No action neede...

Page 80: ...ion scheme Adjust to a lower modulation scheme 813 Timeout occurred after waiting too long to receive a good frame Adjust Receive Threshold 814 Tried too many times at selected speed using V34 modulation scheme Adjust Transmit Level Adjust to a lower modulation scheme 815 Fax transmission was interrupted due to power failure Troubleshoot MFP if error persists See No dial tone on page 2 87 818 Fax ...

Page 81: ...to transmit training successfully in V27 terminal modulation scheme Select a lower Max Speed under Fax Send settings Adjust the Transmit Level Check line quality 888 Failure to transmit training successfully at 2400 bps in V27 terminal modulation scheme Adjust Transmit Level Check line quality 889 Failed to connect at the minimum speed supported by the MFP Adjust Transmit Level Incompatible connec...

Page 82: ...te fax device No action needed A01 Received request for unsupported image width from remote fax device No action needed A02 Received request for unsupported image resolution from remote fax device No action needed A03 Received request for unsupported compression type from remote fax device No action needed A04 Received request for unsupported image length from remote fax device No action needed F0...

Page 83: ...le 2 Replace the ribbon cable Does this fix the problem Problem fixed Go to step 3 3 Replace the cyan LED printhead Does this fix the problem Problem fixed Replace the printhead controller board Step Action and questions Yes No 1 Is the ribbon cable connecting CN3 on the printhead controller board to the black LED head securely connected Go to step 2 Properly connect the ribbon cable 2 Replace the...

Page 84: ...ved Replace the fuser cable 4 Replace the printhead controller board Does this fix the problem Problem solved Go to step 5 5 Replace the fuser Does this fix the problem Problem solved Contact second level support Step Action and questions Yes No 1 Is the fuser properly installed Make sure that it is properly seated Go to step 2 Reinstall the fuser 2 Is the fuser cable properly connected to CN19 on...

Page 85: ...ble 4 Replace the printhead controller board Does this fix the problem Problem solved Go to step 5 5 Replace the fuser Does this fix the problem Problem solved Contact second level support Step Action and questions Yes No 1 Is the fuser properly installed Make sure that it is properly seated Go to step 2 Reinstall the fuser 2 Is the fuser cable properly connected to CN19 on the printhead controlle...

Page 86: ...lem Problem solved Go to step 6 6 Replace the printhead controller board Does this fix the problem Problem solved Go to step 7 7 Replace the LVPS See Low volt power supply removal on page 4 51 Does this fix the problem Problem solved Replace the fuser power cable Step Action and questions Yes No 1 POR the printer a couple times Does the printer turn off a few seconds after the POR Note When restar...

Page 87: ...solved Go to step 4 4 Replace the printhead controller board Does this resolve the issue Problem solved Go to step 5 5 Replace the HVPS Does this resolve the issue Problem solved Contact your second level support Step Action and questions Yes No 1 Is the density sensor cleaner stuck in place Go to step 2 Release the cleaner Replace if damaged 2 Is the cable connecting the density sensor to CN14 on...

Page 88: ...nd Theta sensor Go to step 6 Properly connect the cable to CN8 on the printhead controller board and Theta sensor 6 Is the sensor misaligned the sponge blocking the sensor and the cover opening and closing smoothly Properly align the sensor and reposition the sponge on the theta sensor cover Make sure the cover opens and closes smoothly Go to step 7 7 Replace the theta sensor Problem solved Go to ...

Page 89: ... defective supply item Did this fix the problem Problem solved Replace the drive motor for the affected color Step Action and questions Yes No 1 Is the fuser paper exit motor cable properly connected to the motor and CN16 on the engine board Go to step 2 Connect the cables at both ends 2 Check the cable for continuity Is there continuity Go to step 3 Replace the fuser paper exit motor cable 3 Repl...

Page 90: ...ng the option paper tray to the option connector on the back of the printer Is the cable properly connected on both ends Go to step 3 Go to step 2 2 Connect the cable properly at both ends Does this fix the problem Problem resolved Go to step 3 3 Check the option cable s connection to CN 13 on the printhead controller board Is it properly connected Go to step 4 Go to step 5 4 Check the option cabl...

Page 91: ...onnectivity Is it properly connected Go to step 3 Go to step 2 2 Reconnect the cable to CN 121 Did this fix the problem Problem resolved Go to step 3 3 Check CN 120 on the second expansion paper feeder s expansion feeder controller board for proper connectivity Is it properly connected Go to step 5 Go to step 4 4 Reconnect the cable to CN 120 Did this fix the problem Problem resolved Go to step 5 ...

Page 92: ...03 on the third expansion paper feeder s expansion feeder controller board for proper connectivity Is it properly connected Go to step 7 Go to step 6 6 Reconnect the cable to CN 103 Did this fix the problem Problem resolved Go to step 7 7 Replace the paper full sensor Does this fix the problem Problem resolved Go to step 8 8 Replace the expansion paper feeder controller board Does this fix the pro...

Page 93: ...to step 5 5 Replace the engine power supply cable Does this remedy the situation Problem solved Replace the engine controller board Step Questions actions Yes No 1 Is there anything obstructing the fan s movement Clear the obstruction Go to step 2 2 Check connector CN22 on the engine controller board Is it properly connected Go to step 3 Reconnect the connector 3 Replace the main fan Does this rem...

Page 94: ... Questions actions Yes No 1 POR the device a few times Did the error re occur Go to step 3 Go to step 2 2 POR into the diagnostic menu Run the ASIC test in the Scanner Test menu Did the ASIC pass Problem resolved Go to step 3 3 Replace the RIP Did this fix the issue Problem resolved Contact second level support Step Questions actions Yes No 1 POR the device a few times Did the error re occur Go to...

Page 95: ...3 Replace the RIP board Did this fix the issue Problem resolved Contact second level support Step Questions actions Yes No 1 POR the device a few times Did the error re occur Go to step 2 Problem resolved 2 Replace the RIP Did this fix the issue Problem resolved Contact second level support Step Questions actions Yes No 1 POR the device a few times Did the error re occur Go to step 2 Problem resol...

Page 96: ...place the RIP board Did this fix the issue Problem resolved Contact second level support Step Questions actions Yes No 1 POR the device Did the error re occur Go to step 2 Problem resolved 2 Check all the connections from the ICC card to the ADF relay card and RIP board to ICC card Also check the CCD cables for proper connectivity Are the cables properly connected Go to step 3 Go to step 4 3 Prope...

Page 97: ...o to step 6 Go to step 7 6 Replace the flatbed unit Did this fix the issue Problem resolved Go to step 9 7 Replace the ICC card Did this fix the issue Problem resolved Go to step 8 8 Replace the CCD Did this fix the issue Problem resolved Go to step 9 9 Replace the RIP board Did this fix the issue Problem resolved Contact your second level support Step Questions actions Yes No 1 Remove the ADF pic...

Page 98: ...er path sensors Did this fix the problem Problem resolved Go to step 8 8 Replace the ADF cable Did this fix the problem Problem resolved Go to step 9 9 Replace the controller board Did this fix the problem Problem resolved Contact your next level of support Step Questions actions Yes No 1 Check the FFC ribbon cable connecting the RIP board to the ICC board on the flatbed for proper connectivity Is...

Page 99: ...menu Notes Make sure your printer is connected to a network or to a print server Some printers are designed to restart automatically after a 9yy error On these printers you can retrieve the secondary crash code information using the SE menu Fwedebugs can also be referred to as LBtrace If FWEdebugs does not appear in the list then look for LBtrace Mulitple LBtrace logs can appear in the list of lin...

Page 100: ...rinter_IP_address and then press Enter 2 Click Settings and then select one of the settings page from the links shown on the page 3 Copy all information and then save it as a text file 4 E mail the text file to your next level of support Printing the menu settings page 1 From the home screen navigate to Reports Menu Settings Page 2 Print the menu settings page and then use Scan to E mail to send i...

Page 101: ...o step 3 Go to step 6 3 Check all the cables connected to the RIP board for proper connectivity Are the cables properly connected Go to step 5 Go to step 4 4 Properly connect the cables to the RIP board Restart the device into diagnostic mode Does the 900 xx error reoccur during startup Go to step 5 Go to step 6 5 Replace the RIP board and restart the device Does this fix the problem Note If an er...

Page 102: ... Go to step 31 Problem resolved 16 Is there a modem installed on the device Go to step 17 Go to step 21 17 Reinstall the modem Restart the device Does the 900 xx error reoccur Go to step 18 Go to step 20 18 Upgrade the firmware Contact your next level of support for the correct firmware level to use Restart the printer to operating mode Send the printer a print job Does the 900 xx error reoccur Go...

Page 103: ...r the correct firmware level to use Restart the printer to operating mode Does the 900 xx error reoccur Go to step 30 Go to step 26 30 Replace the faulty ISP option Restart the device Does the 900 xx error reoccur Go to step 31 Go to step 26 31 Contact your next level of support You will need the following information for them Exact 900 xx error digits and complete error message Printed menu setti...

Page 104: ...in the LVPS properly connected Go to step 3 Go to step 2 2 Re connect the cables Did this fix the problem Problem resolved Go to step 3 3 Check the cables for continuity Is there continuity Go to step 5 Go to step 4 4 Replace the cables Did this fix the issue Problem resolved Go to step 5 5 Check pins 1 3 and 7 on CN03 on the LVPS for 5V and pins 5 and 9 for 24V Are the voltages correct Go to step...

Page 105: ...5 EEPROM error Step Action and questions Yes No 1 POR the printer a few times Did this fix the issue Problem resolved Go to step 2 2 Replace the printhead controller Does this fix the problem Problem resolved Go to step 3 3 Replace the RIP board Did this fix the issue Problem resolved Contact your second level support ...

Page 106: ...m board been replaced recently Replace the RIP board with a new and not previously installed system board See RIP board removal on page 4 73 Go to step 3 3 Turn the printer power off for ten or more seconds Then turn the printer back on POR the printer Is the error gone and can the printer print Problem solved Go to step 4 4 Clear the NVRAM of the printer 1 Turn the printer power off 2 With the pr...

Page 107: ...the problem re occur Go to step 2 Problem resolved 2 Put the machine into recovery mode and update the firmware You will need to contact your second level support for the correct firmware level to use Did updating the firmware fix the issue Problem resolved Go to step 3 3 Replace the RIP board Did this fix the problem Problem resolved Call your second level support ...

Page 108: ...his IR allows a user to override the source for the remainder of a job The page will be printed as it is formatted on the paper installed in the tray This may cause clipping No further Change prompts will be posted for the remainder of the current job If the src is MP Feeder Manual Paper or Manual Envelope the string Manual Feeder will be used instead of the src string from the Default Source list...

Page 109: ...the printer job can be cancelled Wait for supplies If job parking is enabled and the job meets all the requirements for allowing the job to be parted the printer adds this message Load source size Load paper in the indicated source and of the indicated size and select Continue Additional messages may include More information the printer will present instructions Cancel Job the printer job can be c...

Page 110: ...the media to continue Remove Paper All bins Remove the paper from all output bins Restore Held Jobs Go Stop If the printer detects Print and Hold or parked jobs stored on the hard disk during Power On Self Test POST Choices are Restore Print jobs are restored and Restoring Held Jobs x y where x is the number of the job restored and y is the total number of jobs to restore You can quit restoring an...

Page 111: ... If the problem still exists replace the printhead controller board See Printhead controller board removal on page 4 37 32 Unsupported Cartridge Check to see if the toner cartridge is a supported cartridge Note Once the cartridge shipped with the printer is exhausted it must be replaced by a supply cartridge refer to the User s Guide for part numbers If the specified toner cartridge is a supported...

Page 112: ...o process current jobs Select Continue to clear the message If this does not fix the problem replace the RIP board See RIP board removal on page 4 73 37 Insufficient memory Some Held Jobs Will Not Be Restored The printer was unable to restore some or all of the confidential or held jobs on the hard disk Select Continue to clear the message If this message occurs again replace the hard drive If thi...

Page 113: ...The job may not print correctly POR the printer If this does not fix the problem replace the PCI card 54 Std Network Software Error Select Continue to clear the message and continue printing The job may not print correctly Program new firmware for the network interface POR the printer If this does not fix the problem replace the PCI card 54 Network x Software Error 55 Unsupported Option in Slot x ...

Page 114: ...removal on page 4 73 58 Too Many Trays Attached 1 Turn off and unplug the printer 2 Remove options until the supported number of options for that model Models C925 supports three additional trays 3 Plug in the printer and turn it on 61 Defective Disk Select Continue to clear the message and continue printing Install a different hard disk before performing any operations that require a hard disk If...

Page 115: ...tact when the fuser is installed Check the cable connectors for damage at the system board and at the LVPS 82 Replace Waste Toner Replace the waste toner box using the instruction sheet that comes with the replacement waste toner box Ensure that there is no interference between the waste toner box and the printer If the problem persists replace the engine board See Engine board MDCONT on page 4 92...

Page 116: ... 37 88 xx color Cartridge Low Show Me View Supplies and Tell Me More displays additional information Replace the specified toner cartridge Select Continue to clear the message and continue printing Check CN17 and 18 on the printhead controller board for proper connectivity If the problem persists replace the printhead controller board See Printhead controller board removal on page 4 37 88 xx color...

Page 117: ...emove paper jammed in the fuser Open the fuser rollers by operating the fuser pressure relief lever If you cannot remove the jam replace the fuser The jam access panel can also be opened After letting the fuser cool unscrew the two thumbscrew and open the access panel You cannot clear the paper jam message To clear the paper jam messages you must remove all paper from the printer paper path Check ...

Page 118: ...er separation pawl Paper will not feed from MPF Be sure you have paper in the MPF Check the paper size and type Does it match the paper setting on the printer Be sure the MPF paper present sensor connector CN16 is connected to the CK1 daughter board If the paper still does not feed go to Paper path service checks on page 2 24 ON OFF switch automatically switching to the Off position Machine shutti...

Page 119: ...roblem Issue resolved Go to step 6 6 Remove the ADF rear cover and inspect the ADF cover closed sensor for dirt and debris Is there dirt and debris present Go to step 7 Go to step 8 7 Remove the ADF rear cover and clean the dirt and debris from the sensor Does this fix the issue Issue resolved Go to step 8 8 Inspect the connections on the ADF relay card in the ADF Are all the connections properly ...

Page 120: ... a properly functioning phone jack Did this fix the problem Problem resolved Go to step 5 5 Is the phone line being used by the MFP an analog line Go to step 8 Go to step 6 6 Is the line being used a VOIP line Go to step 7 Go to step 8 7 Have the system administrator verify that the VOIP server is configured to receive faxes Is the server properly configured Go to step 8 Stop here The issue is VOI...

Page 121: ...ess 411 to enter the SE menu enter Modem settings and select Transmit Level Test by adjusting the transmitted signal strength by decreasing increasing the Transmit Level setting in steps of 1db For example if default value is 11 db changing it to 12db will decrease the signal strength by 1db and changing it to 10db will increase the signal strength by 1db Recommended adjustment range is 5 db in 1d...

Page 122: ...em resolved Go to step 7 7 In diags config menu verify that the Enable Fax Receive setting is on Is the setting set to on Go to step 9 Go to step 8 8 Set Enable Fax Receive to On Did this fix the problem Problem resolved Go to step 9 9 Is Distinctive Ring enabled Go to step 11 Go to step 10 10 Turn on Distinctive ring Did this fix the problem Problem resolved Go to step 11 11 Is the phone line ana...

Page 123: ...ct Receive Threshold Test by adjusting the received signal level by decreasing increasing the Receive Threshold setting in steps of 2db For example if default value is 43 db changing it to 45db will decrease the received signal level by 2db and changing it to 41db will increase the received signal level by 2db Recommended adjustment range is between 33db and 48db in 2db steps Did this fix the prob...

Page 124: ... 6 Fill in the requested information This is where you will type in the information you retrieved in step 3 Second level support can assist you if you have questions about the information requested on the page Note The fields requesting the code levels model number type of problem are auto filled If the information is not in the fields it can be retrieved from the SE menu The SE menu can be access...

Page 125: ...phone line to the modem card and wall jack Did this fix the problem Problem resolved Go to step 3 3 Test the phone line s ability to send and receive calls Did the phone line work properly Go to step 5 Go to step 4 4 Use the MFP on a properly functioning phone jack Did this fix the problem Problem resolved Go to step 5 5 Is the modem card cable properly connected to the system board at J8 and the ...

Page 126: ...oblem resolved Go to step 3 3 Check the printer s online status under Printers and Faxes on the host computer Delete all print jobs in the print queue Is the printer online and in a Ready state Go to step 5 Go to step 4 4 Change the printer status to online Did this fix the issue Problem resolved Go to step 5 5 Does the IP address displayed on the network settings page match the IP address in the ...

Page 127: ...ss network to the printer Did this fix the problem Problem resolved Go to step 17 17 Are the other devices on the wireless network communicating properly Go to step 18 Contact the network administrator 18 Verify that the ISP wireless card cable and any other ISP cables are properly seated in their connectors Are the cables connected correctly Go to step 20 Go to step 19 19 Properly reseat the ISP ...

Page 128: ...new and replaced at the same time Card Remove all the option cards from the device Install each card individually Restart the MFP after each card is installed Remove the card and repeat the previous step with a different card till all cards are checked When a faulty card is found replace the card If the error persists after replacing the option card replace the RIP board See RIP board removal on p...

Page 129: ...he UICC POR the machine into diagnostics mode and perform the button test Do any of the buttons fail the test Go to step 6 Problem solved 6 Replace the RIP board POR the machine into diagnostics mode and perform the button test Do any of the buttons fail the test Contact your second level support Problem solved Step Action and questions Yes No 1 Check the cable connection between the RIP and the U...

Page 130: ...e tray for any damaged or broken parts that would prevent it from being installed properly or move around in the printer Are there loose or damaged parts on the tray Go to step 2 Go to step 3 2 Try a different tray Did this fix the issue Problem resolved Go to step 3 3 Check the sensor cables for proper connection to the sensors and engine controller board Are they properly connected Go to step 5 ...

Page 131: ...r place Go to step 8 Go to step 7 6 Install the paper feed maintenance kit Did this fix the issue Problem solved Contact your second level support Step Action and questions Yes No 1 Are the imaging units properly seated Go to step 3 Go to step 2 2 Reseat the imaging units and properly close the photodeveloper lock Did this fix the issue Problem solved Go to step 3 3 Check the contacts on the rear ...

Page 132: ... assembly If the problem continues replace the RIP board DRAM options This service check is the same as the flash memory option service check with the following exception Run the DRAM Test on page 3 21 from the menu if the DRAM Memory card assembly is correctly installed and not broken or damaged If the test fails replace the DRAM card assembly If the problem continues replace the RIP board Step A...

Page 133: ... test depending on the disk size This test leaves the hard disk unformatted The servicer or user must reformat the disk using the Format Disk Menu operation This is a destructive type of test All the data on the disk is destroyed and should not be performed on a known good disk Network card option The network is installed on the system board on network model printers See Networking service check o...

Page 134: ... unit to CN03 on the LVPS are connected properly Go to step 7 Properly connect the cables 7 Replace the switch Did this fix the problem Problem solved Go to step 8 8 Are the fuses blown on either supply Go to step 9 Go to step 10 9 Replace the power supply with the blown fuse Did this fix the problem Problem solved Go to step 10 10 Check CN03 on the scanner power supply for the following voltages ...

Page 135: ...e for continuity Is there continuity Go to step 6 Go to step 7 6 Replace the defective cable Did this fix the problem Problem solved Go to step 7 7 Replace the printhead Did this fix the problem Problem solved Go to step 8 8 Replace the printhead controller board Did this fix the problem Problem solved Contact you second level support Step Action and questions Yes No 1 Is the transfer belt positio...

Page 136: ...or locking door Pull the toner bottle out and push it back in to position Close the photoconductor locking unit door Did this fix the problem Problem solved Tell the customer that this issue can occur Instruct them to perform the procedure performed in step 1 Go to step 2 2 Clean the waste toner bottle sensor of any debris or toner Did this fix the issue Problem solved Go to step 3 3 Check the cab...

Page 137: ...step 7 7 Replace the sensor Did this fix the issue Problem resolved Go to step 8 8 Replace the engine board Did this fix the issue Problem resolved Contact your second level support Step Action and questions Yes No 1 Remove the tray and move the paper size guides to different positions Are the size pins moving when the length guide is moved Go to step 3 Go to step 2 2 Try a different paper standar...

Page 138: ...sensor and ADF paper length sensors for dirt or debris Are the sensors clear Go to step 4 Go to step 3 3 Clear the sensors of dirt and debris Did this fix the problem Problem resolved Go to step 4 4 Check the sensors for proper connection to J3 on the ADF relay card Are they properly connected Go to step 6 Go to step 5 5 Reconnect the cables Did this fix the problem Problem resolved Go to step 6 6...

Page 139: ...ing up processing data or printing Solid green The printer is on but idle Solid red Operator intervention is required 3 Sleep Enables Sleep Mode or Hibernate Mode The following actions wake the printer from Sleep Mode Touching the screen or any hard buttons Opening an input tray cover or door Sending a print job from a computer Performing a Power on Reset POR 4 Keypad Lets you enter numbers letter...

Page 140: ...plays a warning or error message whenever the printer requires intervention to continue processing Touch this to access the messages screen for more information on the message and how to clear it Tips Opens context sensitive Help information on the touch screen Note All menus have a Tips button USB Displays files on a flash drive Bookmarks Allows you to create organize and save a set of bookmarks ...

Page 141: ...ol panel Cancel Jobs not pictured Opens the Cancel Jobs screen The following items are available under the Print Fax and Network headings Print job Copy job Fax profile FTP E mail send Each heading shows up to three jobs per screen If more than three jobs exist in a column then an arrow appears enabling you to scroll through the jobs Select a job to cancel it Button Function Submit Saves settings ...

Page 142: ...Exits from the current screen to the home screen Tips Opens context sensitive Help on the touch screen Icon Function Accept Confirms selections and moves to the next screen Stop Cancel Cancels an action or selection Cancels out of a screen and return the previous screen Return Navigates back to the previous screen Unselected radio button Indicates that an item is not selected Button Function ...

Page 143: ...lected radio button Indicates a selection Index Displays information about the key functions of the printer including instructions on how to operate it Search Lets you search for files and menus Warning Indicates a warning or error condition Icon Function ...

Page 144: ...Print Settings Setup Menu Finishing Menu Quality Menu Job Accounting Menu Utilities Menu XPS Menu PDF Menu Postscript Menu PCL Emul Menu HTML Menu Network Ports Active NIC Standard Network Standard USB Parallel x Serial x SMTP Setup Security Miscellaneous Security Settings Confidential Print Disk Wiping Security Audit Log Set Date and Time Reports Menu Settings Page Device Statistics Network Setup...

Page 145: ... are infrequently required by a user Generally the options made available in this menu group are used to configure a printer for operation See Configuration Menu on page 3 9 for more information Network SE menu While in Network Ports Menu press and hold 9 7 and 6 SE menu At the printer perform the following steps 1 In the Admin menu navigate to Network Ports Standard Network Std Network Setup menu...

Page 146: ... off the printer 2 Press and hold 2 7 and 8 3 Turn on the printer 4 Release the buttons when the splash screen appears This mode will allow the printer to boot from a secondary set of instructions to allow a code flash to the printer Code can be flashed from a PC via USB ...

Page 147: ... Maintenance Counter on page 3 10 Reset Transfer Belt Counter See Reset Transfer Belt Counter on page 3 11 USB Scan To Local See USB Scan to Local on page 3 11 Black Only Mode See Reset Maintenance Counter on page 3 10 Print Quality Pages See Print Quality Pages on page 3 11 Fuser Speed See Fuser Speed on page 3 11 Reports See Reports on page 3 11 Color Trapping See Color Trapping on page 3 11 Tra...

Page 148: ... Color Alignment on page 3 14 ADF Edge Erase See ADF Edge Erase on page 3 14 FB Edge Erase See FB Edge Erase on page 3 14 Scanner Manual Registration See Scanner Manual Registration on page 3 14 Disable Scanner See Disable Scanner on page 3 14 Paper Prompts See Paper Prompts on page 3 14 Envelope Prompts See Envelope Prompts on page 3 14 Action for Prompts See Action for Prompts on page 3 15 Jobs ...

Page 149: ...in graphics Use this test to identify print quality problems The Test Pages must be printed on A4 Legal or Letter paper Fuser Speed Use this setting if the device is encountering a shock line issue After adjusting the setting the device will print the Print Quality Pages It is recommended that this menu setting is used under the guidance of your second level of support Reports From this menu you c...

Page 150: ...rpreter is available Download Emuls Warning This setting should not be changed without specific instructions from the next level of support This setting temporarily disables downloaded emulators for troubleshooting purposes All downloaded emulators are re enabled automatically after two PORs Demo Mode This printer supports a demo mode that is usually used in retail environments to illustrate the f...

Page 151: ...ad Job Assist When this setting is set to On a user can initiate scanner related jobs and enter values for a limited number of settings related to those jobs using the keypad Touch Back to exit without changing the setting Format Fax Storage This setting enables you to format the non volatile storage used for storing faxes Note If an advanced password has been established you must enter this passw...

Page 152: ... that will be erased For copies the printed page will always have a at least a 2 mm no print border The larger of the 2 mm no print border and the Edge Erase setting will be used in this situation Scanner Manual Registration Use this menu to adjust the scanner margins after you replace any of the following parts Flatbed scanner assembly ADF unit assembly Flatbed scanner CCD assembly For more infor...

Page 153: ...n This setting appears only if a hard disk is installed the disk is not read only and Disk Encryption is enabled Warning When the settings are changed all data on the hard disk is deleted Erase all information on Disks This setting performs a wipe of the printer hard disk erasing all data Warning Wipe Disk deletes all data on the printer hard disk including downloaded fonts macros and held jobs Do...

Page 154: ...priate level of stability Disabling this setting deletes the file Key Repeat Initial Delay This setting determines the length of delay before a repeating key starts repeating The default setting is 1 second You can adjust the setting by 25 second increments Key Repeat Rate This setting indicates the number of presses per second for repeating keys The default setting is 15 presses per second Clear ...

Page 155: ... inactive on the Home screen for a length of time equal to the Screen Timeout setting in the Timeouts section of the General Settings Menu Any IR that does appear on the panel will give the user the option of returning to the Home screen without clearing it From the Home screen the user can initiate any other workflow or feature as usual Once the device returns to the Home screen though any existi...

Page 156: ... Press and hold 3 and 6 3 Turn on the printer 4 Hold the buttons until the splash screen appears Diagnostic mode menus SCANNER CALIBRATION See SCANNER CALIBRATION on page 3 20 Copy Quick Test Adjust Calibration Values Reset Calibration Values PRINT TESTS See PRINT TESTS on page 3 20 Tray 1 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed Multi Purpose Feeder Print Qu...

Page 157: ... Defaults See Defaults on page 3 24 Prt Color Pg Count See PAGE COUNTS on page 3 25 Prt Mono Pg Count Perm Page Count Serial Number See Serial Number on page 3 25 Model Name See Model Name on page 3 25 Configuration ID See Configuration ID on page 3 25 Par 1 Strobe Adj if installed See REPORTS EVENT LOG Display Log See Display Log on page 3 26 Print Log See Print Log on page 3 27 Clear Log See Cle...

Page 158: ...installed in the selected input source If a source is selected that contains paper then a page similar to the Quick Test Page is printed and does not contain the Print Registration diamonds If a source is selected which contains envelopes then an Envelope Print Test pattern is printed This pattern contains only text which consists of continuous prints of each character in the selected symbol set I...

Page 159: ... to HARDWARE TESTS Button Test With no buttons pressed an image the operator panel buttons is displayed Press each operator panel button one at a time and the button in the illustration turns blue 2 Press Stop X or touch Back to exit the test DRAM Test This test checks the validity of DRAM both standard and optional The test repeatedly writes patterns of data to DRAM to verify that each bit in mem...

Page 160: ...e the test finishes the screen updates with the result P and F represent the same numbers for DRAM If the test passes the Pass Count increases by 1 However if the test fails one of the following failure messages appears for approximately three seconds and the Fail Count increases by 1 Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Em...

Page 161: ... Test Test Passed appears if the test passes Quick Disk Test Test Failed appears if the test fails 2 Press Stop X or touch Back to return to the Device Tests menu Disk Test Clean Warning This test destroys all data on the disk and should not be attempted on a good disk This test may run approximately 1 hours depending on the disk size 1 From the Diagnostics menu navigate to DEVICE TESTS Disk Test ...

Page 162: ...n the Input Tray Tests menu To run the Input TrayTest 1 From the Diagnostics menu touch INPUT TRAY TESTS 2 Select the input source 3 Select either Single or Continuous Note If Single is selected no buttons are active while the input device is feeding If Continuous is selected Stop X can be pressed to cancel the test 4 At the end of the test the printer returns to the INPUT TRAY TESTS menu PRINTER ...

Page 163: ...Configuration ID 1 or Configuration ID 2 whenever you replace the system board The IDs consist of eight hexadecimal characters including 0 through 9 and A through F Note When the printer detects a Configuration ID that is not defined or invalid the following occurs The default standard model Configuration ID is used instead Configuration ID is the only function available in DIAGNOSTICS Unless the ...

Page 164: ...ecreases the sample time by 50 ns per increment Touch Back to return to the Diagnostics menu REPORTS From this menu you can print the Menu Settings Page or the Event Log EVENT LOG Display Log Display Log shows the message that appeared on the operator panel for each event in the log starting with the most recent Use the touch screen arrows to scroll through the log entries To see more in depth inf...

Page 165: ...service RIP software errors Code versions of all packages when error occurred Panel message when error occurred except for 900 service RIP software errors Debug information and secondary error codes depending on the error The Clear Log operation clears out the errors that print in this report The errors listed in the Display Log operation do not necessarily match in number nor in order with the er...

Page 166: ...ntire length of the flatbed Press Stop X to end the test Sensor Test This test checks each scanner related sensor and returns Closed or Open for each Sensor ADF Paper Present 0 means paper is not present in the ADF Sensor FB Cover Open 0 means the flatbed cover is down Sensor Home Sensor 1 means the CCD is in the home position Sensor Skew Sensor 0 means the actuator is in the up position Sensor AD...

Page 167: ...irst transfer to the ITU and second transfer to the media 5 Fuse the toner to the media 6 Clean erase the photoconductor and the ITU In summary the printer s controller board receives print data and the command to print The controller board then initiates the print process The controller board is the command center for the EP process and coordinates the various motors and signals The high voltage ...

Page 168: ...e it for the LED Service tips If the surface of the charge roller is damaged such as a nick or pit it will cause the charge to be uneven on the photoconductor This will cause a repeating mark on the printed page Check the service manual for the repeating marks table If the charge roller is severely damaged the surface of the photoconductor will not be charged properly and heavy amounts of toner wi...

Page 169: ...ctor surface Service tips Never touch the surface of the photoconductor with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the photoconductor will have to be replaced The surface of the photoconductor is coated with an organic substance that makes it s...

Page 170: ...e similar to using glue to write on a can and then rolling it over glitter The glitter sticks to the glue but won t stick to the rest of the can Service tips Never touch the surface of the developer roller with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page ...

Page 171: ...onductors and the transfer belt Service tips Never touch the surface of the transfer belt with your bare hand The oil from your skin will cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the transfer belt will have to be replaced Don t use solvents or other cleaners to clean the transfer belt sur...

Page 172: ...lings to the media and the entire image is transferred from the transfer belt to the media Service tips If the transfer roller has nicks pits or flat spots on it the surface doesn t come into contact with the media and transfer unit properly This will cause voids or light spots on the page or repeating voids light areas because the toner can t be fully transferred due to the charge difference in t...

Page 173: ... off the page or cause paper jams Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an improper media setting Always check the paper type setting before replacing the fuser A common mistake is to print on heavier media such as cardstock with the paper type set to plain paper When removing paper jams from the fuser be sure to use the fuser release tabs to relieve the pre...

Page 174: ... Once the toner image on the transfer belt has been transferred to the page the transfer belt rotates around and is cleaned by the cleaning blade This occurs for every page that is printed After the toner is moved to the cleaning blade the toner is moved from the cleaning blade to the waste toner area using an auger system Cleaning blade Waste toner box Fuser Transfer belt Second transfer roller T...

Page 175: ...fer belt from the photoconductors a cleaning blade scrapes the remaining toner from the surface of each photoconductor This is the clean erase process Now the photoconductor surface is prepared to begin the EP cycle once again This cleaning erasing cycle happens after each plane of color is transferred to the transfer belt Cleaning blade ...

Page 176: ...ay 1 and Tray 2 Tray 1 uses a spring loaded plate to engage the media in the tray with the pickup roller Tray 2 uses a tray lift motor to lift the paper to the paper feed mechanism Tray 1 holds approximately 150 sheets of 20lb paper and Tray 2 holds about 250 sheets of 20lb paper Tray 1 does not have automatic size sensing therefore the correct paper size must be set on the paper size wheel locate...

Page 177: ...r size is sensitive so positioning the Tray Guides 1 or 2 notches out of position could result in an incorrect paper size reading If any Paper Jams 34 Short paper messages or other paper feed problems occur check the paper size in the tray against the size the printer thinks is loaded You can view the paper size in the Paper Menu Multipurpose feeder The MFP holds about 50 sheets of 20lb paper and ...

Page 178: ...ator roll rotates backwards to prevent multiple sheets of paper from feeding The paper moves to the feed roll and is fed into the paper path Paper Pick roll Separator roll torque limiter Paper feed motor Paper feed clutch Std Registration roller IN Feed roll Transport Clutch Regisration roll OUT A B a b c Normal feed Multi feed Friction A B Feed roll Pick roll Separator roll Torque limiter Frictio...

Page 179: ...n the MPF tray one by one Once the duplex exit MPF detection lever senses the leading edge of the media at the duplex exit roller it engages the duplex re feed clutch to transport the sheet of paper into the paper path Duplex transport upper roller Duplex exit roller Duplex exit MPF sensor actuator Timing belt MPF feed clutch Duplex clutch Paper feed roller Paper MPF tray Lower duplex transport ro...

Page 180: ...s the Fuser Entry Detection Sensor and enters the Fuser Here heat and pressure are applied to the page to bond the image permanently to the media The toner is impregnated with wax so it releases from the fuser rolls without the need of a wiper or oil coating roller The Fuser Rollers continue to feed the paper upward to the Fuser Exit Sensor and Fuser Exit Rolls Paper exit If the sheet is single si...

Page 181: ...de of the printer Once the paper reaches the bottom the Duplex Exit MPF detection lever senses the leading edge of the media at the Duplex Exit Roller and it engages the Duplex re feed clutch to transport the sheet of paper into the EP paper path Note Once the media reaches the Duplex Exit MPF detection lever it shares the same paper path as the MPF Transfer roll Paper Paper Paper MPF Registration...

Page 182: ...F paper path sensor 4 ADF cover open ADF paper path sensor 5 Pick roll ADF pick roll CRU 6 Pick roll position sensor Photo interrupt ADF paper path sensor 7 Feed roll ADF pick roll CRU 8 Separator roll ADF Separator roll CRU 9 Paper gap sensor photo interrupt ADF paper path sensor 10 Paper in sensor Photo reflect Scan sensor 11 Scan roller ADF main feed unit 12 Scan sensor Photo interrupt Scan sen...

Page 183: ...ecuting the pick the pick roll is in the up position If the sensor determines that the roll is in the up position the pick roll is moved to the down position to initiate the pick 4 With the pick roll in the proper position the signal to pick is generated from the ADF relay card The top sheet in the paper is pulled in to the ADF towards the feed roll To prevent double feeds a separator roll is pres...

Page 184: ...per path If the scan job is simplex the duplex gate is positioned to direct the media to the exit roller and the media exits the ADF to the output bin 12 The reversed exit roll pulls the paper back into the ADF The transport roll then moves the media to the paper in sensor When the paper in sensor is actuated the exit roll stops Also the paper in sensor indicates that this is the second side of th...

Page 185: ... conversion tables For example it is possible to apply one type of color conversion table to text while applying a different color conversion table to photographic images Should I use PostScript or PCL emulation What settings produce the best color The PostScript driver is strongly recommended for best color quality The default settings in the PostScript driver provide the preferred color quality ...

Page 186: ...f the Embedded Web Server Selecting any sample set generates a multiple page printout consisting of hundreds of colored boxes Either a CMYK or RGB combination is located on each box depending on the table selected The observed color of each box is obtained by passing the CMYK or RGB combination labelled on the box through the selected color conversion table To print Color samples from the printer ...

Page 187: ...dent on the value entered in the RGB or CMYK Increment box To access a detailed Color Samples set from the Embedded Web Server 1 Open a Web browser 2 In the address bar type the network printer IP address 3 Click Configuration 4 Click Color Samples 5 Click Detailed Options to narrow the set to one color range 6 When the Detailed Options page appears select a color conversion table 7 Enter the RGB ...

Page 188: ...3 50 Service Manual 7541 03x Go Back Previous Next ...

Page 189: ...y static electricity 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 a...

Page 190: ...achine place the old RIP card back in the machine and start it up After the machine startup shut down the machine and install the new RIP card After installing the new RIP card restart the machine and let it go through the startup cycle After this procedure is completed successfully there is no need to adjust any settings If the above procedure fails you must contact the technical support center f...

Page 191: ... exported by clicking the selection box next to the app 7 Choose Export If the Web page cannot be accessed or an error persists despite trying to boot in Invalid Engine code mode then there is no way to backup the eSF apps The technician needs to make the customer aware that the applications and their setting could not be saved Note There is a size limit on the export file 128kb Because of this it...

Page 192: ...ns the duplex unit and paperfeed unit sub component removals have their own sections They are Duplex unit component removals on page 4 173 Paperfeed unit component removals on page 4 178 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 CAUTION Remove the power...

Page 193: ...Repair information 4 5 7541 03x Go Back Previous Next Cover Removals RIP cover 1 Remove the two screws securing the RIP cover to the RIP cage 2 Remove the RIP cover ...

Page 194: ... Previous Next Scanner power supply access cover 1 Press the access cover inward at the arrow and pull back removing the cover Cord cover 1 Remove the screw A securing the right side of the cord cover to the rear cover and scanner frame ...

Page 195: ... screw B securing the left side of the cord cover to the rear cover and scanner frame 3 Tilt the cord cover back and lift it up and away from the rear of the scanner Rear cover 1 Remove the cord cover See Cord cover on page 4 6 2 Remove the screw A above the rear fan ...

Page 196: ...4 8 Service Manual 7541 03x Go Back Previous Next 3 Remove the two screws B in the lower left corner 4 Remove the screw C in the lower left corner ...

Page 197: ...Repair information 4 9 7541 03x Go Back Previous Next 5 Remove the screw D in the upper right corner 6 Remove the screw E in the top middle of the cover ...

Page 198: ... to the side frame 9 Remove the option connector cover 10 Use the flatblade screwdriver to pry the rear cover away from the side cover at the main fan 11 Use a small flatblade screwdriver to release the tabs G that fasten the option connector cable to the rear cover 12 Pull the rear cover away from the device Note If there are ISP cards installed remove the thumbscrews from the RIP cage G ...

Page 199: ...Repair information 4 11 7541 03x Go Back Previous Next Front op panel cover 1 Remove the one screw A on the front right side 2 Remove the two screws B on the on the inner left side of the cover ...

Page 200: ...4 12 Service Manual 7541 03x Go Back Previous Next 3 Remove the two screws C on the under side of the cover 4 Pull the cover back 5 Disconnect the USB cable D from the cover ...

Page 201: ...3x Go Back Previous Next Op panel top cover 1 Remove the card reader cover See Front op panel cover on page 4 11 2 Remove the two screws A on the front of the cover 3 Remove the screw B in the upper left corner of the panel assembly ...

Page 202: ...corner of the panel assembly 5 Release the tabs on the inside of the cover and gently lift the top cover assembly away from the bottom cover 6 Disconnect the speaker cable D from the UICC 7 Disconnect the grey and blue USB cables E from the UICC 8 Disconnect the RIP UICC cable F from the UICC ...

Page 203: ...41 03x Go Back Previous Next Op panel bottom cover 1 Remove the op panel top cover 2 Remove the three screws A that secure the op panel bottom cover to the flatbed assembly 3 Lift the cover up and away from the flatbed assembly ...

Page 204: ...al 7541 03x Go Back Previous Next Upper right cover 1 Remove the op panel bottom cover See Op panel bottom cover on page 4 15 2 Remove the screw A at the rear of the cover 3 Remove the screw B at the front of the cover ...

Page 205: ...03x Go Back Previous Next 4 Lift the cover up so it clears the tabs C and pull it away from the printer Output bin print engine top cover 1 Open the front cover 2 Remove the two screws A securing the top cover to the printer frame ...

Page 206: ... the one screw B on the left side above the scanner power supply door 4 Use a flatbed screwdriver to release the tabs C on the top cover from the printer frame 5 Lift and remove the top cover Back cave cover 1 Remove the inner right cover 2 Remove the top cover ...

Page 207: ...s Next 3 Remove the two screws A on the left side of the back cave cover 4 Remove the cover Inner right cover 1 Remove the upper right cover 2 Remove the lower op panel cover 3 Remove the front screw A that secures the inner right cover to the frame ...

Page 208: ... Manual 7541 03x Go Back Previous Next 4 Remove the screw B that secures the front of the inner right cover to the back cave cover 5 Remove the two screws C that fasten the rear cave cover to the inner right cover ...

Page 209: ...nformation 4 21 7541 03x Go Back Previous Next 6 Use a screw driver to release the four tabs D that secure the inner right cover to the back cave cover 7 Pull the inner right cover forward and out of the device ...

Page 210: ...val 1 Remove the rear cover See Rear cover on page 4 7 2 Remove the top cover See Output bin print engine top cover on page 4 17 3 Remove the rear screw A securing the left cover to the printer frame 4 Remove the screw B securing the left cover to the left EMI shield ...

Page 211: ...Repair information 4 23 7541 03x Go Back Previous Next 5 Remove the two screws C securing the left cover to the frame 6 Remove the screw D securing the left cover to the printer frame D ...

Page 212: ...4 24 Service Manual 7541 03x Go Back Previous Next 7 Slide the left cover back to release the tabs from the printer frame 8 Pull the left cover away from the frame ...

Page 213: ...1 03x Go Back Previous Next Speaker removal 1 Remove the front operator panel cover 2 Remove the top operator panel cover 3 Remove the four screws A that secure the speaker cover to the op panel bottom cover 4 Remove the speaker ...

Page 214: ...op removals Output bin full sensor actuator removal 1 Remove the op panel paper exit guide See Op panel paper exit guide removal on page 4 32 2 Remove the screw A from the op panel paper exit guide 3 Remove the screw B from the op panel paper exit guide ...

Page 215: ...Repair information 4 27 7541 03x Go Back Previous Next 4 Remove the screw C from the op panel paper exit guide 5 Remove the top cover of the guide ...

Page 216: ...4 28 Service Manual 7541 03x Go Back Previous Next 6 Use a flatblade screwdriver to release the actuator from the exit guide 7 Remove the actuator ...

Page 217: ... Not a FRU on page 4 106 4 Remove the toner cartridges and imaging units 5 Disconnect the affected LED s ribbon cable from the printhead controller board 6 Guide the printhead ribbon cable through the top of the print engine 7 Remove the head holder screw A securing the LED holder to the top frame Note You will need to remove the top EMI shield to access the screw if you are removing the magenta o...

Page 218: ... the LED assembly towards the front of the print engine Note Use two hands when removing the unit This is to prevent the LED assembly from dropping down and damaging the LED unit in the assembly Note Perform a color alignment after installing the new printhead See Color Alignment on page 3 14 ...

Page 219: ...on page 4 29 2 Using a screw driver pull the plastic casing A on the rear of the holder away from the tab on the printhead releasing it from the printhead holder 3 Repeat the previous step for the front of the printhead assembly 4 Remove the printhead from the LED assembly 5 Carefully remove the ribbon cable B from the printhead ...

Page 220: ...7541 03x Go Back Previous Next Op panel paper exit guide removal 1 Remove the paper output bin See Output bin print engine top cover on page 4 17 2 Remove the two screws A on the front 3 Remove the two screws B in the rear ...

Page 221: ... the top cover 2 Remove the op panel paper exit guide See Op panel paper exit guide removal on page 4 32 3 Disconnect the paper exit bin full sensor cable from CN7 on the printhead controller board 4 Thread the cable A through the fuser fan duct 5 Remove the screw B securing the paper exit guide to the sub drive unit ...

Page 222: ...Service Manual 7541 03x Go Back Previous Next 6 Remove the screw C securing the paper exit guide to the rear of the printer frame 7 Pull the fuser duct back to provide some clearance for the paper exit unit ...

Page 223: ...03x Go Back Previous Next 8 Lift the unit up and remove it from the printer Note When reinstalling the unit line up the slots D on the paper exit unit with the tabs E on the sub drive unit before pushing the unit down in place D EE ...

Page 224: ...e the paper exit guide See Paper exit guide removal on page 4 33 2 Release the tabs A securing the black exit guide 3 Open the guide exposing the bin full sensor 4 Release the tabs B securing the bin full sensor to the paper exit guide 5 Disconnect the blue cable from the sensor A B ...

Page 225: ...ad controller board Engine board Replace only 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 both of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning 1 Remove the rear...

Page 226: ... the scanner support 5 Remove the screw B securing the cable box to the top shield 6 Remove the screws securing the top shield 7 Disconnect all the cables from printhead controller board Warning Be careful to avoid damaging the ribbon cables when removing them from the printhead controller board A B ...

Page 227: ...head controller board to the frame Top EMI sheild removal 1 Remove the output bin cover See Output bin print engine top cover on page 4 17 2 Remove the two front screws A that secure the top EMI shield to the printer frame 3 Remove the screws B that secure the top sheild to the rear EMI sheild C A A B ...

Page 228: ...4 40 Service Manual 7541 03x Go Back Previous Next Front removals Transfer belt CRU 1 Open the front cover 2 Open the right cover 3 Lower the transfer belt door ...

Page 229: ...tward till the two green handles appear on the top of the unit 5 Use the two handles to pull the unit all the way out Transfer belt position sensor removal 1 Remove the transfer belt 2 Remove the sensor cable from the belt position sensor 3 Press the tabs the fasten the belt position sensor to the printer frame ...

Page 230: ...aper size sensor removal This is the paper size sensor for the top MPF tray 1 Remove the standard paper tray 2 Remove the MPF paper tray 3 Remove the 15 screws A securing the sensor support frame to the print engine frame 4 Remove the paper size sensors ...

Page 231: ...tion 4 43 7541 03x Go Back Previous Next Photoconductor lock removal 1 Remove the standard paper tray 2 Remove the two screws A that secure the front metal cover to the printer frame 3 Remove the photoconductor lock ...

Page 232: ... to the left side of the printer frame 3 Twist the stopper downward to release the two pawls B 4 Insert a flat blade screwdriver at point C 5 Pull the stopper forward to disengage the stopper from the printer frame 6 Disengage the pawls D by tuning them in the direction indicated by the arrow 7 Push the stopper up at point C to disengage the stopper from the frame ...

Page 233: ...vious Next Left side removals Left EMI shield removal not a FRU 1 Remove the top cover See Output bin print engine top cover on page 4 17 2 Remove the left cover See Left cover removal on page 4 22 3 Remove the screw A 4 Remove the three screws B ...

Page 234: ...4 46 Service Manual 7541 03x Go Back Previous Next 5 Remove the two screws C 6 Remove the two screws D ...

Page 235: ...Repair information 4 47 7541 03x Go Back Previous Next 7 Remove the one screw E 8 Remove the four screws F on top ...

Page 236: ...4 48 Service Manual 7541 03x Go Back Previous Next 9 Remove the two screws G on top 10 Remove the two screws H ...

Page 237: ...Repair information 4 49 7541 03x Go Back Previous Next 11 Remove one screw I 12 Remove the screw J ...

Page 238: ...4 50 Service Manual 7541 03x Go Back Previous Next 13 Carefully insert the screwdriver through the main fan and remove the one screw K 14 Remove the Left EMI shield ...

Page 239: ...bles connected to the power supply 3 Remove the three screws A securing the top of power supply to the power supply cage CAUTION SHOCK HAZARD Remove power from the printer before continuing or use caution if the product must be energized during this procedure The heat sink transformer core presents risk of electric shock Test before touching ...

Page 240: ...4 52 Service Manual 7541 03x Go Back Previous Next 4 Remove the three screws B securing the bottom of power supply to the power supply cage ...

Page 241: ... fan See Rear fan on page 4 102 3 Disconnect the engine board fan cable from the engine board 4 Disconnect the main fan cable from CN22 on the engine board 5 Remove the screw A fastening the main fan stay to the left EMI shield 6 Remove the screw B fastening the main fan stay to the rear of the printer frame ...

Page 242: ...4 54 Service Manual 7541 03x Go Back Previous Next 7 Thread the fan cable through the cable stay 8 Lift the fan up and pull the main fan stay away from the printer ...

Page 243: ...be mounted with label pointed outwards 1 Remove the left side EMI shield 2 Remove the fan s wiring harness from the connector A on the shield Note The harness must be routed in this matter when the fan is reinstalled 3 Turn the shield over and remove the four screws B securing the fan to the shield ...

Page 244: ...power supply See Scanner power supply removal on page 4 58 3 Remove the 7 screws A securing the power box shield to the printer frame 4 Disconnect the theta sensor harness from the theta sensor 5 Remove the one screw B securing the theta sensor mounting plate to the printer frame 6 Remove the two screws C securing the theta sensor to the mounting plate B C D ...

Page 245: ...upply removal on page 4 51 2 Remove the scanner power supply See Scanner power supply removal on page 4 58 3 Remove the 7 screws securing the power box shield to the printer frame 4 Disconnect the density sensor harness from the density sensor 5 Remove the two screws D fastening the density sensor to the frame B C D ...

Page 246: ...Next Main switch 1 Remove the main power switch cable 2 Disconnect both harnesses A from the power switch Scanner power supply removal 1 Remove the left cover 2 Remove the left EMI shield 3 Disconnect the three cables from the scanner power supply ...

Page 247: ...Repair information 4 59 7541 03x Go Back Previous Next 4 Remove the four screws A from the top of the scanner power supply 5 Remove the screw B from the lower right corner of the scanner power supply ...

Page 248: ...4 60 Service Manual 7541 03x Go Back Previous Next 6 Remove the screw C from the lower left corner of the scanner power supply ...

Page 249: ...Repair information 4 61 7541 03x Go Back Previous Next Right side removals Fuser removal 1 Open the right side door 2 Grab the handles on the fuser and gently pull the fuser out of the print engine ...

Page 250: ...4 62 Service Manual 7541 03x Go Back Previous Next Handle cover removal 1 Remove the two screws A securing the handle covers to the printer frame 2 Remove the handle cover ...

Page 251: ...move the high voltage power supply See HVPS removal on page 4 111 2 Remove the handle covers See Handle cover removal on page 4 62 3 Open the right cover and remove the transfer roll Warning Avoid damaging the transfer roll 4 While holding the right cover lift the duplex unit ...

Page 252: ...4 64 Service Manual 7541 03x Go Back Previous Next 5 Disconnect the two springs from the right cover 6 Disconnect the left and right link arms from the duplex pin covers on the right cover ...

Page 253: ...air information 4 65 7541 03x Go Back Previous Next 7 Disconnect the duplex clutch and sensor cables from the connectors B on the engine controller board 8 Disconnect the duplex ground wire from the frame ...

Page 254: ...4 66 Service Manual 7541 03x Go Back Previous Next 9 Route the duplex cables through the frame 10 Slide the duplex to the right freeing it from the left hinge ...

Page 255: ...lex away from the printer while carefully routing the cables through the right hinge on the printer 12 Remove the screws securing the duplex unit to the right cover Note See Duplex unit component removals on page 4 173 for instructions to remove the duplex sub components ...

Page 256: ...oval on page 4 63 3 Using a flatblade screwdriver gently push the tab securing the link arm to the link arm stay back and remove the right link arm Note Use care when pushing the tab back It can easily break if pushed too far 4 Disconnect the registration clutch harness from connector CN20 on the printhead controller board 5 Disconnect the pick roll separator roll and feed roll clutch cables from ...

Page 257: ...Repair information 4 69 7541 03x Go Back Previous Next 8 Remove the four screws A fastening the paperfeed mount plate to the right scanner stay ...

Page 258: ...4 70 Service Manual 7541 03x Go Back Previous Next 9 Remove the two screws B securing the right side of the paper feed unit to the printer frame ...

Page 259: ...41 03x Go Back Previous Next 10 Remove the two screws C securing the upper left side of the paper feed unit to the printer frame 11 Remove the two screws D securing the lower left side of the paper feed unit to the printer frame ...

Page 260: ...the unit Note When routing the cables through the frame be sure to make a note of where they go through the frame Note See Paperfeed unit component removals on page 4 178 for instructions to remove the paperfeed unit sub components Transfer Roll CRU 1 Open the right side cover duplex unit 2 Turn the transfer roll fasteners to the unlocked position ...

Page 261: ...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 cannot be used in another printer It must be returned to the manufacturer CAUTION POTENTIAL INJURY There is danger of explosion if a lithium battery is incorrectly replaced Replace it only with the same or an ...

Page 262: ...Previous Next 6 Remove the fourteen screws B securing the RIP board to the RIP cage Crossbar removal not a FRU 1 Remove the RIP cage 2 Remove the five screws A securing the cross bar to the rear EMI shield and the vertical scanner supports ...

Page 263: ...e the HVPS unit See HVPS removal on page 4 111 2 Remove the rear fan See Rear fan on page 4 102 3 Disconnect the engine board fan cable from the engine board 4 Disconnect all the cables from the engine board 5 Remove the screw A from the upper right corner 6 Remove the screw B from the lower right corner ...

Page 264: ...4 76 Service Manual 7541 03x Go Back Previous Next 7 Remove the screw C from the upper left corner 8 Remove the screw D from the lower left corner 9 Pull the board and frame away from the printer frame ...

Page 265: ...ve unit cover not a FRU 1 Remove the HVPS unit See HVPS removal on page 4 111 2 Disconnect the drive unit motor cables from CN 17 18 19 and 20 on the engine board 3 Remove the screw A from the upper right corner 4 Remove the screw B from the lower right corner ...

Page 266: ...ack Previous Next 5 Remove the screw C from the upper left corner 6 Remove the screw D from the lower left corner 7 Slide the drive unit cover away from the drive unit being careful to avoid damaging the contact springs on the sub unit ...

Page 267: ...over not a FRU on page 4 77 2 Remove the engine board and engine board mounting bracket See Engine board and mount removal not a FRU on page 4 75 3 Disconnect the drive motor wiring harnesses from the engine board 4 Remove the three screws A in the upper left corner 5 Remove the screw B between the two leftward motors A ...

Page 268: ...4 80 Service Manual 7541 03x Go Back Previous Next 6 Remove the screw C between the two rightward motors 7 Remove the screw D securing the fan cage to the scanner support D ...

Page 269: ...Repair information 4 81 7541 03x Go Back Previous Next 8 Push the fan cage back 9 Remove the two screws E in the upper right corner E ...

Page 270: ...4 82 Service Manual 7541 03x Go Back Previous Next 10 Remove the screw F in the lower right corner 11 Remove the two screws G in the center bottom of the drive unit F G ...

Page 271: ...otor C M Y K Note All four motors use this procedure 1 Remove the drive unit 2 Place the drive unit with the motors down on a table 3 Remove the two screws A securing the motor to the drive unit Note Note When replace the drive motor be careful to not damage the gears in the drive unit with the metal gear on the motor H ...

Page 272: ...n See Rear fan on page 4 102 7 Disconnect the engine board fan cable from the engine board 8 Remove the op panel paper exit guide See Op panel paper exit guide removal on page 4 32 9 Remove the paper exit guide See Paper exit guide removal on page 4 33 10 Remove the fuser fan from the fuser duct This part does not need to be removed from the machine 11 Remove the black fuser duct This is not a FRU...

Page 273: ...Repair information 4 85 7541 03x Go Back Previous Next 13 Disconnect the cables A from the blade connectors on the interlock switch 14 Disconnect the fuser paper exit motor cable B ...

Page 274: ...vice Manual 7541 03x Go Back Previous Next 15 Using a long shaft screwdriver remove the two black plastite screws C securing the sub drive cover to the sub drive unit 16 Remove the black plastic sub drive cover ...

Page 275: ...epair information 4 87 7541 03x Go Back Previous Next 17 Remove the screw D at the bottom of the sub drive unit 18 Remove the screw E at the middle of the sub drive unit above the fuser paper exit motor ...

Page 276: ...t 19 Remove the screw F at the top of the sub drive unit Note If you are replacing the unit place the ground wire on the new unit 20 Pull the portion of the unit with the motor and sensors out of the machine 21 Disconnect the fuser entry sensor cable ...

Page 277: ...Lift and remove the gear train portion of the sub drive unit out of the printer Door interlock switch removal 1 Remove the sub drive unit See Sub drive unit removal on page 4 84 2 Remove the two screws A securing the door interlock switch to the sub drive unit ...

Page 278: ...ious Next Duplex solenoid removal 1 Remove the sub drive unit See Sub drive unit removal on page 4 84 2 Remove the left screw A securing the solenoid to the sub drive unit 3 Remove the right screw B securing the solenoid to the sub drive unit ...

Page 279: ...mation 4 91 7541 03x Go Back Previous Next Fuser entry sensor removal 1 Remove the sub drive unit See Sub drive unit removal on page 4 84 2 Depress the tabs A fastening the fuser entry sensor to the sub drive unit ...

Page 280: ...r screws A securing the board to the bracket Fuser Fan 1 Remove the rear EMI shield See Rear EMI shield Not a FRU on page 4 106 2 Remove the fuser duct 3 Remove the HVPS See HVPS removal on page 4 111 4 Remove the rear fan See Rear fan on page 4 102 5 Disconnect the fuser fan cable from CN21 the engine controller board 6 Remove the fuser fan Note Make sure the rating label is facing outward when r...

Page 281: ...d See Rear EMI shield Not a FRU on page 4 106 2 Disconnect the cable from the connector A exit drive unit motor 3 Remove the two screws B that secure the exit drive unit motor to the fuser motor damper Note The ground wire C is connected with one of the screws Be sure to replace the ground wire when replacing the motor ...

Page 282: ...m cable A from CN U14 on the RIP board 2 Loosen the two screws B that secure the modem to the RIP cage 3 Pull the modem up and inward to remove it from the cage Papertray lift motor removal 1 Remove the HVU See HVPS removal on page 4 111 2 Remove the rear fan See Rear fan on page 4 102 B ...

Page 283: ... B securing the paper tray lift motor to the frame RIP cage removal Note The RIP board does not need to be removed to perform this procedure 1 Remove the rear cover See Rear cover on page 4 7 2 Disconnect all the cables from the RIP board 3 Remove the screw A securing the bottom of the RIP cage to the rear EMI shield and crossbar ...

Page 284: ...4 96 Service Manual 7541 03x Go Back Previous Next 4 Remove the two screws B securing the upper left corner of the RIP cage to the EMI shield 5 Remove the six screws C on the inside of the RIP cage ...

Page 285: ...ove the drive unit See Drive unit on page 4 79 2 Remove the printhead controller board Printhead controller board removal on page 4 37 3 Remove the three screws A securing the board stay to the printer frame 4 Remove the five screws B securing the head pin plate to the printer frame ...

Page 286: ... Service Manual 7541 03x Go Back Previous Next 5 Remove the ten screws C securing the top support rail not a FRU to the top frame 6 Remove the four printhead assemblies See LED assembly removal on page 4 29 ...

Page 287: ...information 4 99 7541 03x Go Back Previous Next 7 Remove the twelve screws D securing the top frame to the printer 8 Remove the four screws E securing the plastic body back to the left and right printer frames ...

Page 288: ...Previous Next 9 Remove the screws F securing the toner sensors to the top frame Transfer belt motor removal 1 Remove the HVPS 2 Disconnect the motor harness A from the transfer belt 3 Remove the two screws B securing the motor to the frame ...

Page 289: ...xt Temperature and humidity sensor removal 1 Remove the rear cover The sensor will be located to the right side of the right rear scanner support 2 Disconnect the sensor cable A from the sensor 3 Remove the screw B securing the sensor to the printer frame ...

Page 290: ...o Back Previous Next Rear fan 1 Remove the high volt power supply See HVPS removal on page 4 111 2 Remove the three screws A securing the fan mounting duct to the printer 3 Route the high volt power supply cable the fan mounting duct ...

Page 291: ...Repair information 4 103 7541 03x Go Back Previous Next 4 Disconnect the fan cable B from the MDCONT engine board ...

Page 292: ...e Manual 7541 03x Go Back Previous Next Sub frame unit 1 Remove the drive unit 2 Disconnect the belt up down sensor harness A if it is connected 3 Remove the four screws B securing the sub unit to the head in plate ...

Page 293: ...on 4 105 7541 03x Go Back Previous Next Paper size switch removal 1 Remove the HVPS See HVPS removal on page 4 111 2 Disconnect the three cables 3 Remove the two screws A securing the sensor mount to the printer frame ...

Page 294: ...n place Rear EMI shield Not a FRU 1 Remove the rear cover See Rear cover on page 4 7 2 Remove the RIP cage See RIP cage removal on page 4 95 3 Remove the cross bar See Crossbar removal not a FRU on page 4 74 4 Remove the two silver screws A securing the top rear of the EMI shield to the frame ...

Page 295: ...Repair information 4 107 7541 03x Go Back Previous Next 5 Remove the four screws B on the upper right side of the shield 6 Remove the two screws C on the lower right side of the shield ...

Page 296: ...4 108 Service Manual 7541 03x Go Back Previous Next 7 Remove the screw D in the lower left corner of the shield 8 Remove the two screws E in the upper left corner ...

Page 297: ...Repair information 4 109 7541 03x Go Back Previous Next 9 Remove the upper screw F securing the emi shield to the cage 10 Remove the lower screw G securing the emi shield to the cage ...

Page 298: ...e the three cables out of the guides Paper feed motor removal 1 Remove the paper feed unit See Power supply fan removal on page 4 55 2 Disconnect the cable A from the paper feed motor 3 Remove the two screws B securing the paper feed motor to the paper feed unit ...

Page 299: ... page 4 7 2 Remove the top cover See Output bin print engine top cover on page 4 17 3 Remove rear EMI shield See Rear EMI shield Not a FRU on page 4 106 4 Remove three screws A attaching the HVU to the frame Note The upper left screw is different than the other two 5 Pinch the nylon retainer B to free the board ...

Page 300: ...ar fan on page 4 102 3 Depress the tabs A securing the waste toner sensor to the frame and push the sensor in After the sensor is detached pull it out of the frame 4 Disconnect the waste toner sensor cable B from the sensor Installation note Using a small flatblade screwdriver gently press the actuator of the waste toner towards the front of the print engine while reinstalling the waste toner sens...

Page 301: ...u For more information see Adjustments on page 4 211 ADF assembly removal 1 Remove the cord cover See Cord cover on page 4 6 2 Remove the rear cover 3 Remove the two thumbscrews A that secure the ADF cable to the flatbed assembly 4 Remove the thumbscrews securing the ADF and flatbed hinges to the flatbed 5 Tilt the ADF assembly up and lift it away from the flatbed assembly Note After installing th...

Page 302: ...4 114 Service Manual 7541 03x Go Back Previous Next ADF pick roll removal 1 Open the ADF top cover 2 Pull the tab 1 down 2 3 Remove the ADF pick roll ...

Page 303: ...03x Go Back Previous Next ADF separator roll removal 1 Open the ADF top cover 2 Pull the separator roll lock 1 up 3 Pull the separator roll shaft holder 2 up 4 Pull the lock 3 off the shaft 5 Take the separator roll 4 off the shaft ...

Page 304: ...ver See Rear cover on page 4 7 5 Disconnect the flatbed cables A from the RIP 6 Using a short handle screw driver remove the two screws B on the left underside of the flatbed platform 7 Using a short handle screw driver remove the two screws C on the right underside of the flatbed platform 8 Remove the flatbed from the scanner platform 9 Remove the flatbed front cover See Flatbed front cover on pa...

Page 305: ...ormation 4 117 7541 03x Go Back Previous Next Flatbed front cover 1 Remove the flatbed assembly from the flatbed platform 2 Turn the flatbed over on a non marring surface 3 Remove the screw A 4 Remove the screw B ...

Page 306: ...4 118 Service Manual 7541 03x Go Back Previous Next 5 Remove the screw C 6 Remove the screw D ...

Page 307: ...Repair information 4 119 7541 03x Go Back Previous Next 7 Remove the screw E ...

Page 308: ...isconnect the haptics cable A from the UICC 3 Remove the UICC cable B from the UICC 4 Disconnect the ribbon cable C from the UICC 5 Remove the four screws D securing the UICC to the upper operator panel assembly Note When reattaching the UICC cable to the display and the UICC card ensure that the end of the cable with the black tape to the display ...

Page 309: ...C See UICC removal on page 4 120 3 Disconnect the UICC cable A from the touchscreen from the touchscreen 4 Remove the seven screws B securing the touchscreen to the upper operator panel assembly Note When reattaching the UICC cable to the display and the UICC card ensure that the end of the cable with the black tape is connected to the display ...

Page 310: ... relay board 1 Remove the ADF relay board cover See ADF relay card cover on page 4 168 2 Disconnect the ADF cable ground A from the relay board 3 Disconnect all the cables from the relay board 4 Remove the other screw securing the board to the ADF assembly ...

Page 311: ...he print engine 3 Place the scanner glass side down on a non marring surface 4 Remove the 5 screws securing the shield to the flatbed assembly 5 Remove the shield from the flatbed assembly 6 Remove the two screws that secure the ADF cable connector to the bottom shield 7 Disconnect all the cables from the ICC board 8 Remove the five screws A securing the board to the flatbed assembly ...

Page 312: ...nual 7541 03x Go Back Previous Next CCD chassis 1 Remove the flatbed upper cover 2 Remove the screw A securing the CCD guide rod to the flatbed frame 3 Remove the screw B securing the CCD guide rod to the flatbed frame ...

Page 313: ...Repair information 4 125 7541 03x Go Back Previous Next 4 Slide the guide rod towards the CCD chassis and remove the chassis from the rod 5 Disconnect the ribbon cables C from the CCD chassis ...

Page 314: ...sis Note After installing the new CCD perform the scanner calibration procedures See Adjustments on page 4 211 CCD belt 1 Remove the flatbed upper cover 2 Disconnect the belt from the clip on the right side 3 Disconnect the belt from the spring on the left side of the flatbed 4 Remove the belt from the CCD chassis ...

Page 315: ... facedown on a non marring surface and remove the bottom shield 3 Disconnect the affected sensor s cable from the ICC board 4 Turn the flatbed rightside up 5 Remove the flatbed upper cover 6 Remove the screw A securing the affected sensor to the flatbed assembly 7 Lift the sensor and thread the sensor cable through the bottom of the flatbed assembly ...

Page 316: ...Next ADF cable 1 Remove the cord cover See Cord cover on page 4 6 2 Remove the left ADF cover 3 Remove the ADF relay card cover 4 Disconnect the ground cable from the ADF relay board A 5 Disconnect the ground cable from the ADF main feeder chassis B ...

Page 317: ...air information 4 129 7541 03x Go Back Previous Next 6 Disconnect the ADF cable C from the ADF relay board ADF motor frame 1 Remove the left ADF cover 2 Disconnect the motor cables from the ADF relay card ...

Page 318: ...4 130 Service Manual 7541 03x Go Back Previous Next 3 Remove the two screws A securing the motor frame to the ADF main feeder unit ...

Page 319: ...Repair information 4 131 7541 03x Go Back Previous Next 4 Remove the motor frame from the ADF unit Note When replacing the frame make sure the ADF drive clutch stop B is properly aligned with the clutch ...

Page 320: ...oid 1 Remove the ADF main feeder 2 Remove the four screws A securing the solenoids to the ADF main feeder ADF drive clutch 1 Remove the ADF main feeder unit 2 Remove the clip A securing the ADF drive clutch to the shaft 3 Slide the ADF drive clutch off the shaft ...

Page 321: ...ormation 4 133 7541 03x Go Back Previous Next ADF input tray 1 Remove the screw A under the front side of the ADF input tray 2 Remove the screw B under the rear side of the ADF input tray 3 Open the ADF top cover ...

Page 322: ... tray and disconnect the tray paper present sensor cable ADF main feeder 1 Remove the left ADF cover 2 Remove the right ADF cover 3 Disconnect the cables from the ADF relay card 4 Disconnect the ground wire A from the ADF main feeder 5 Remove the ADF motor frame assembly A ...

Page 323: ...5 7541 03x Go Back Previous Next 6 Remove the three screws B securing the right side of the ADF main feeder to the top flatbed cover 7 Remove the screw C securing the right side of the ADF main feeder to the top flatbed cover ...

Page 324: ...ide of the ADF main feeder to the top flatbed cover 9 Remove the main feeder from the flatbed cover 10 Remove the solenoids 11 Remove the ADF clutch 12 Remove the Inner ADF top cover 13 Remove the ADF paper guide Note After reinstalling the new component perform the scanner calibrations See Adjustments on page 4 211 ...

Page 325: ...der on page 4 134 2 Remove the clip A securing the ADF clutch to the transport roll shaft 3 Slide the clutch off the shaft ADF hinge 1 Remove the ADF unit from the scanner assembly 2 Place the ADF unit upside down on a non marring surface 3 Remove the four screws A the secure the hinge to bottom of the flatbed cover ...

Page 326: ...er assembly 2 Place the ADF unit upside down on a non marring surface 3 Remove the four screws A the secure the hinge to bottom of the flatbed cover Tray paper size sensors 1 Remove the ADF input tray from the ADF unit 2 Remove the three screws A fastening the tray bottom to the ADF input tray top ...

Page 327: ...Repair information 4 139 7541 03x Go Back Previous Next 3 Release the tab B securing the tray top to the tray bottom 4 Release the tab C securing the tray top to the tray bottom ...

Page 328: ... 03x Go Back Previous Next 5 Release the tab D securing the tray top to the tray bottom 6 Release the tab E securing the tray top to the tray bottom 7 Pull the tabs F back to release the width sensor cable from the tray bottom ...

Page 329: ...Repair information 4 141 7541 03x Go Back Previous Next 8 Remove the two screws G securing the paper width actuator to the rack gear 9 Remove the size sensors from the ADF input top ...

Page 330: ...h sensor to the ADF paper tray ADF cover open ADF pick sensor Note The ADF cover open and ADF pick sensor are one assembly 1 Remove the flatbed upper cover 2 Disconnect the sensor cable A from the connector on the sensor 3 Remove the screw B securing the sensor cable to the ADF inner cover B ...

Page 331: ...e screw C securing the sensor to the inner cover 5 Remove the screw D securing the ADF pick sensor to the inner cover ADF cover open sensor actuator 1 Remove the screw securing the cover open sensor to the ADF inner cover 2 Remove the ADF cover open sensor actuator C D ...

Page 332: ... one assembly 1 Remove the ADF outer cover 2 Disconnect the sensor assembly A cable from the main cover sensor cable 3 Remove the screw B holding the cable to the ADF inner cover 4 Remove the screw C securing the ADF paper in sensor to the ADF inner cover 5 Remove the screw D securing the paper present sensor to the ADF inner cover B C D ...

Page 333: ...or 1 Remove the screw securing the ADF paper present sensor to the ADF inner cover 2 Turn the actuator up and carefully remove the actuator from the inner ADF to cover Paper in sensor actuator 1 Remove the ADF paper in sensor 2 Carefully remove the actuator from the inner ADF to cover ...

Page 334: ...Note The scan sensor FRU assembly is made of the scan sensor and an optical paper path jam sensor 1 Remove the ADF main feed unit 2 Remove the scan sensor cover 3 Remove the screw A securing the scan sensor to the scan sensor cover 4 Remove the two screws B securing the paperpath sensor to the ADF main feed unit ...

Page 335: ...Repair information 4 147 7541 03x Go Back Previous Next 5 Pull the scan sensor cable through the clip on the ADF main feed unit 6 Pull the sensor cable through the side of the ADF main feed unit ...

Page 336: ...4 148 Service Manual 7541 03x Go Back Previous Next Scan sensor actuator 1 Remove the scan sensor 2 Use a flatbed screwdriver to free the actuator from the scan sensor cover 3 Remove the actuator ...

Page 337: ...7541 03x Go Back Previous Next Scan sensor cover not a fru 1 Remove the ADF main feed unit 2 Use a flatblade screwdriver to remove the guide on the bottom of the ADF main feed unit 3 Pull the guide out of the ADF main feed unit ...

Page 338: ...50 Service Manual 7541 03x Go Back Previous Next 4 Remove the screw A securing the scan sensor cover to the ADF main feed unit 5 Remove the screw B securing the scan sensor cover to the ADF main feed unit ...

Page 339: ...r information 4 151 7541 03x Go Back Previous Next 6 Remove the screw C securing the scan sensor cover to the ADF main feed unit 7 Remove the screw D securing the scan sensor cover to the ADF main feed unit ...

Page 340: ...x Go Back Previous Next 8 Remove the screw E securing the scan sensor cover to the ADF main feed unit 9 Remove the scan sensor cover Duplex timing sensor 1 Remove the ADF main feed unit 2 Remove the fastener A 3 Remove the gear B ...

Page 341: ...Repair information 4 153 7541 03x Go Back Previous Next 4 Turn the bushing C to release it from the ADF main feed unit 5 Remove the screw D securing the paper guide to the ADF main feed unit ...

Page 342: ...4 154 Service Manual 7541 03x Go Back Previous Next 6 Turn the bushing E to release it from the ADF main feed unit 7 Remove the screw F securing the paper guide to the ADF main feed unit ...

Page 343: ...information 4 155 7541 03x Go Back Previous Next 8 Lift the paper guide up and feed the duplex pass timing sensor cable through the ADF main feeder frame 9 Release the cable from the clip G on the paper guide ...

Page 344: ...4 156 Service Manual 7541 03x Go Back Previous Next 10 Carefully pull the sensor PCBA away from the retainer H on the paper guide 11 Carefully lift the sensor up and away from the paper guide ...

Page 345: ...x Go Back Previous Next Duplex out scan out sensor 1 Remove the ADF main feed unit 2 Remove the screw a securing the duplex out sensor to the ADF main feed unit 3 Route the cable out of the main feed unit removing the clips if needed ...

Page 346: ...l 7541 03x Go Back Previous Next Duplex out sensor actuator 1 Remove the duplex out sensor 2 Remove the two screws A that fasten the sensor mount to the ADF main feed unit 3 Lift the actuator out of the ADF main feed unit ...

Page 347: ...Previous Next Flatbed cover closed sensor 1 Remove the flatbed upper cover See Flatbed upper cover on page 4 161 2 Remove the two screws a securing the sensor mounting bracket to the flatbed chassis 3 Remove the sensor cable from the connector ...

Page 348: ...4 160 Service Manual 7541 03x Go Back Previous Next 4 Pull the two tabs B back to release the sensor from the mounting bracket ...

Page 349: ...d upper cover 1 Remove the flatbed assembly See Flatbed assembly removal on page 4 116 2 Remove the flatbed front cover See Flatbed front cover on page 4 117 3 Remove the two screws A on the front of the flatbed unit 4 Remove the screw B on the front of the cover ...

Page 350: ... screws C on the top rear of the cover 6 Remove the two screws D on the top rear of the cover 7 Lift the cover off of the flatbed chassis Flatbed scanner cables removal 1 Remove RIP cover see RIP cover on page 4 5 2 Disconnect the scanner FFC cable A from J3 on RIP card ...

Page 351: ...Repair information 4 163 7541 03x Go Back Previous Next 3 Disconnect the scanner cable B from J4 on RIP card B A ...

Page 352: ...x Go Back Previous Next Outer ADF top cover 1 Open the ADF top cover 2 Remove the left cover screw A that secures the outer cover to the inner cover 3 Remove the middle cover screw B that secures the outer cover to the inner cover ...

Page 353: ... Back Previous Next 4 Remove the right cover screw C that secures the outer cover to the inner cover Inner ADF top cover 1 Remove ADF outer top cover 2 Remove the ADF main feeder 3 Remove the screw A securing the hinge to the main feeder ...

Page 354: ...4 166 Service Manual 7541 03x Go Back Previous Next 4 Remove the hinge 5 Pull the inner top cover away from the ADF main feeder ...

Page 355: ...k Previous Next 6 Carefully feed the sensor assembly cable through the ADF main feeder 7 Carefully feed the sensor assembly cable through the ADF paper guide assembly 8 Remove sensors and hinges from the inner cover to place on the new cover ...

Page 356: ...Service Manual 7541 03x Go Back Previous Next ADF relay card cover 1 Remove the two screws A securing the relay cover to the ADF assembly Left ADF cover 1 Remove the two screws A on top of the left ADF cover ...

Page 357: ...Repair information 4 169 7541 03x Go Back Previous Next 2 Remove the screw B in the rear of the left ADF cover 3 Lift the ADF top cover and remove the screw C ...

Page 358: ...4 170 Service Manual 7541 03x Go Back Previous Next 4 Lift the cover up and slide the tab on the cover out of the ADF assembly ...

Page 359: ...formation 4 171 7541 03x Go Back Previous Next Right ADF cover 1 Remove the screw A securing the cover to the flatbed cover 2 Lift the ADF top cover and remove the screw B securing the cover to the flatbed cover ...

Page 360: ...4 172 Service Manual 7541 03x Go Back Previous Next 3 Lift the rear of the right ADF cover up and pull the cover away from the flatbed cover ...

Page 361: ...ls Duplex clutch removal 1 Remove the duplex unit See Duplex removal on page 4 63 2 Remove the two screws A securing the duplex cover to the duplex unit 3 Disconnect the duplex clutch harness from the duplex clutch 4 Remove the e clip B that fastens duplex clutch to the carrying shaft ...

Page 362: ...clutch See Duplex clutch removal on page 4 173 2 Remove the timing belts Duplex exit MPF sensor removal 1 Remove the duplex unit See Duplex removal on page 4 63 2 Remove the duplex exit MPF sensor actuator 3 Disconnect the sensor harness 4 Pinch the tabs C that secure the sensor to the duplex unit C ...

Page 363: ...1 Remove the duplex unit See Duplex removal on page 4 63 2 Remove the two screws A securing the MPF clutch cover to the duplex unit 3 Remove the e clip B securing the clutch to the MPF shaft 4 Remove the MPF shaft C 5 Remove the MPF paper empty lever D 6 Remove the MPF clutch ...

Page 364: ... 03x Go Back Previous Next MPF tray assembly removal 1 Open the MPF tray 2 Slide the MPF arm up to the opening on the tray A 3 Pull the arm out of the tray 4 Repeat steps 1 and 2 for the other arm 5 Remove the MPF roller cover ...

Page 365: ...Repair information 4 177 7541 03x Go Back Previous Next 6 Lift and pull the tray away from the printer ...

Page 366: ...tructions Separating the MPF tray and main tray paperfeed units 1 Remove the paperfeed unit from the printer See Power supply fan removal on page 4 55 2 Remove the clutches on the paperfeed unit See Paperfeed unit clutch removal on page 4 184 3 Remove the two screws A securing the paperfeed motor to the paperfeed motor frame 4 Remove the seven screws B securing the paperfeed motor frame to the pap...

Page 367: ...ct frame to the paperfeed units 7 Remove the eight screws D securing the paperfeed connect frame to the paperfeed units Main tray paper guide removal Note This is not a FRU 1 Remove the paper feed unit See Paper feed unit removal on page 4 68 2 Place the paper feed unit on its side with the paper guides facing up ...

Page 368: ... to the paper feed unit 4 With the tab depressed gently lift the paper guide up 5 Use a flatblade screwdriver to gently remove the guide spring from the paper feed unit Note The spring should remain on the paper guide 6 Remove the outer main tray paper guide from the paper feed unit This guide will be used on the new paper feed unit ...

Page 369: ...8 Gently lift and remove the inner main paper guide from the paper feed unit This guide will be used on the new paper feed unit Multi purpose feed tray paper guide removal Note This is not a FRU 1 Remove the paper feed unit See Paper feed unit removal on page 4 68 2 Place the paper feed unit on it s side with the paper guides facing up ...

Page 370: ... a flatblade screwdriver to re route the registration sensor cables around the guide on the outer paper guide 4 Carefully disconnect the cable from the registration sensor 5 Route the sensor cable around the two remaining cable guides on the outer paper guide ...

Page 371: ... the paper feed unit 7 With the tab depressed gently lift the paper guide up 8 Use a flatblade screw driver to gently remove the guide spring from the paper feed unit Note The spring should remain on the paper guide 9 Remove the outer multi purpose tray paper guide from the paper feed unit This guide will be used on the new paper feed unit ...

Page 372: ... will be used on the new paper feed unit Paperfeed unit clutch removal Note This procedure applies to all the clutches on the paperfeed unit 1 Remove the paperfeed unit See Power supply fan removal on page 4 55 2 Disconnect the wiring harness A from the clutch 3 Remove the e clip B securing the clutch to the shaft Note When reinstalling the clutch make sure the clutch stopper on the paperfeed unit...

Page 373: ...he cassette guide releasing the sensor 4 Disconnect the sensor from the sensor wire harness B Registration sensor actuator removal Note The paperfeed unit does not need to be removed from the printer 1 Open the right cover door 2 Pull the cassette guide down 3 Place a flatbed screwdriver under the right side of the actuator using it as a lever to pull the actuator shaft out of the cassette guide A...

Page 374: ...nit Torque limiter removal 1 Remove the separator roll See Separator roll removal on page 4 189 2 Remove the torque limiter Upper and lower registration springs removal 1 Remove the paperfeed unit See Power supply fan removal on page 4 55 2 Remove the clutches on the paperfeed unit See Paperfeed unit clutch removal on page 4 184 3 Separate the two paperfeed units See Separating the MPF tray and ma...

Page 375: ...Repair information 4 187 7541 03x Go Back Previous Next 4 Remove the registration gears A 5 Remove the e clips B 6 Remove the registration bushings C 7 Remove the registration springs D ...

Page 376: ...fan removal on page 4 55 2 Depress the tab A and remove the PE sensor actuator 3 Pull back the tab on the pick roll B and remove the pick roll Paperfeed roll removal 1 Remove the paperfeed unit See Paper feed unit removal on page 4 68 2 Remove the pick roll See Pick roll removal on page 4 188 3 Remove the nylon retainer clip C 4 Remove the feed roll ...

Page 377: ...us Next Separator roll removal 1 Lower the duplex unit to the down position 2 Remove the outer cassette guide A 3 Remove the inner cassette guide B 4 Remove the plastic e clip C that secures the separator roll to the shaft 5 Remove the separator roll ...

Page 378: ...ay and main tray paperfeed units on page 4 178 for instructions 1 Remove the static discharge brush plate top feeder only 2 Remove the static discharge brush top feeder only 3 Remove the registration roll gears A 4 Remove the e clips B securing the registration rolls to the paperfeed unit 5 Remove the bushings C holding the registration roll to the paperfeed unit 6 Remove the registration springs ...

Page 379: ...nformation 4 191 7541 03x Go Back Previous Next MPF roll removal 1 Remove the MPF arms A from the MPF tray and right cover 2 Lower the MPF tray 3 Remove the MPF roller cover 4 Slide the MPF coupling to the left ...

Page 380: ...4 192 Service Manual 7541 03x Go Back Previous Next 5 Take the MPF shaft out 6 Remove the MPF roll ...

Page 381: ...xt MPF pad removal 1 Remove MPF tray See MPF tray assembly removal on page 4 176 2 Gently pull the right side of the pad holder cover and disconnect it from the mount A 3 Gently pull the left side of the pad holder cover and disconnect it from the mount B ...

Page 382: ...4 194 Service Manual 7541 03x Go Back Previous Next 4 Remove the right screw C securing the outer pad holder to the MPF unit 5 Remove the left screw D securing the outer pad holder to the MPF unit ...

Page 383: ...rmation 4 195 7541 03x Go Back Previous Next 6 Pull the outer pad holder away from the machine 7 Carefully lift and remove the pad from the pad holder Note Reuse the spring that was between the pad and pad holder ...

Page 384: ...e You will need to remove the drive gear spring and washer on the paper exit roll and place it on the new paper exit roll 1 Remove the paper exit unit See Paper exit guide removal on page 4 33 2 Remove the e clip A that fastens the exit unit roll to the paper exit unit 3 Remove the bushing B ...

Page 385: ...Repair information 4 197 7541 03x Go Back Previous Next 4 Remove the e clip C securing the drive gear to the shaft 5 Remove the drive gear D from the shaft ...

Page 386: ...4 198 Service Manual 7541 03x Go Back Previous Next 6 Remove the spring washer e clip and bushing E from the shaft 7 Release the tabs F that secure the black guide to the exit unit ...

Page 387: ...Repair information 4 199 7541 03x Go Back Previous Next 8 Open the paper exit unit exposing the rollers 9 Pull back the tab G to release the roller ...

Page 388: ...1 03x Go Back Previous Next 10 Remove the screw H that fastens the roller holder to the paper exit unit frame 11 Pull the roller holder back and away from the paper exit unit 12 Repeat steps 9 thru 11 for the remaining rollers ...

Page 389: ...Repair information 4 201 7541 03x Go Back Previous Next 13 Move the paper exit guide roll to the left lift it out of the frame and pull it to the lift releasing it from the paper exit unit ...

Page 390: ... tray from the option paper feed unit 2 Remove the clip A securing the paper feed roll to the shaft 3 Slide the paper feed roll B off the shaft to remove it Pick roll removal 1 Remove the paper tray from the option paper feed unit 2 Pull back the tab A on the pick roll 3 Slide the pick roll B off of the shaft to remove it ...

Page 391: ...securing the separator roll to the shaft 3 Slide the separator roll B off the shaft to remove it Paper size switches removal 1 Remove the paper tray from the option paper feed unit 2 Disconnect the cables A from the sensors 3 Remove the two screws B securing the sensor mounting bracket to the option tray rear frame 4 Remove the switches C from the bracket ...

Page 392: ... to the rear of the tray 5 Remove the sensor from the option paperfeed drawer Transport sensor removal 1 Take the main printer unit off of the option paper feed unit 2 Remove the screw A securing the transport sensor bracket to the option feeder 3 Disconnect the harness from the transport sensor 4 Remove the transport sensor from the mounting bracket by pressing the tabs B on the sensor together a...

Page 393: ...e frame by pressing the tabs A on the sensor together and pulling it away from the frame 3 Disconnect the sensor from the harness Paper full sensor removal 1 Take the main printer unit off of the option paper feed unit 2 Remove the paper empty sensor from the frame by pressing the tabs A on the sensor together and pulling it away from the frame 3 Disconnect the sensor from the harness ...

Page 394: ... all the cables from the option controller board 3 Remove the four screws A securing the controller board to the rear frame Stepper motor removal 1 Remove the rear cover 2 Remove the stepper motor cable from the controller board 3 Remove the three screws A securing the bracket to the rear frame 4 Remove the gear and belt ...

Page 395: ...s Next 5 Remove the two screws B securing the stepper motor to the bracket Tray lift motor removal 1 Remove the rear cover 2 Disconnect the tray lift cable from the tray lift motor 3 Remove the three screws A securing the tray lift motor to the frame ...

Page 396: ...t Option door inter lock switch removal 1 Remove the rear cover 2 Disconnect the interlock cable from the interlock switch 3 Remove the one screw A securing the bracket to the frame 4 Remove the one screw B securing the interlock switch to the bracket ...

Page 397: ...Remove the screw B securing the right rear cover 3 Remove the screw C securing the right rear switch cover 4 Remove the two screws D securing the vertical transport guide rail 5 Remove the vertical transport cover 6 Remove the two screws E securing the right middle cover 7 Remove the screw F securing the vertical transport guide plate F ...

Page 398: ...4 210 Service Manual 7541 03x Go Back Previous Next 8 Remove the two screws G securing the rear cover to the option feeder 9 Remove the left and right drum stays H 10 Remove the clutch ...

Page 399: ...ostics menu navigate to SCANNER CALIBRATION Copy Quick Test c Compare the copy to the original test page and then navigate to Adjust Calibration Values ADF Front Black d Adjust the values and then touch Submit to save your changes Increasing the value makes the black level darker e To check the changes reload the original test page and then repeat the Copy Quick Test Repeat the steps as needed unt...

Page 400: ... hold 2 and 6 turn on the printer and release the buttons when the splash screen appears 2 Navigate to Scanner Manual Registration Print Quick Test 3 Adjust the flatbed a Place the printed test page facedown on the flatbed scanner glass and select Copy Quick Test b Compare the copy to the original test page c Select Flatbed and adjust the left and top margins as needed d Touch Submit to save your ...

Page 401: ...Go Back Previous Next 5 Locations Locations Print engine cross section Callout no Part name 1 Charge roll 2 LED head 3 Developer roll 4 Primary transfer roll 5 Drum cleaning blade 6 Photoconductor 7 Doctor blade 8 Supply roll ...

Page 402: ...up roll Std tray 23 Feed roll Std tray 24 Separator roll Std tray 25 Registration roll IN MP feeder 26 Registration roll OUT MP feeder 27 Registration roll IN Std tray 28 Registration roll OUT Std tray 29 Duplex input roll 30 Duplex transport roll 31 Duplex bottom transport roll 32 Duplex exit roll 33 Paper exit roll 34 Registration sensor actuator 35 Fuser input sensor actuator 36 Duplex exit sen...

Page 403: ... timing sensor 3 ADF paper present photo interrupt ADF paper path sensor 4 ADF cover open ADF paper path sensor 5 Pick roll ADF pick roll CRU 6 Pick roll position sensor Photo interrupt ADF paper path sensor 7 Feed roll ADF pick roll CRU 8 Separator roll ADF Separator roll CRU 9 Paper gap sensor photo interrupt ADF paper path sensor 10 Paper in sensor Photo reflect Scan sensor 11 Scan roller ADF m...

Page 404: ...5 4 Service Manual 7541 03x Go Back Previous Next Rip Board connectors ...

Page 405: ..._FB_CDU 7 5V_SCANNER 8 FB_PWRSVR_R 9 FBR_AFE_SH_R 10 FBR_AFE_SEN_R 11 FBR_AFE_SCK_R 12 FBR_AFE_SDIO_R 13 GND 14 FBR_AFE_NRST_R 15 GND 16 FB_LVDS_RXIN0 17 FB_LVDS_RXIN0 18 GND 19 FB_LVDS_RXIN1 20 FB_LVDS_RXIN1 21 GND 22 FB_LVDS_RXIN2 23 FB_LVDS_RXIN2 24 GND 25 FB_LVDS_RXCLK 26 FB_LVDS_RXCLK 27 GND 28 FB_LVDS_MCLK 29 FB_LVDS_MCLK 30 GND ...

Page 406: ... TOP_FB_CN 7 BOOT_SEL_CN 8 5V SCANNER 9 5V SCANNER 10 GND 11 MDC_TXD_CN 12 MDC_RXD_CN 13 GND 14 ADF_PAPER_PRES_R 15 FB_COVER_CLOSING_R 16 GND 17 FB_NHOME_R 18 ADF_INTERVAL_R 19 GND 20 MDC_RST_NR 21 3 3V 22 GND 23 NC_MDC_23 24 IC2_CLK 25 IC2_DATA 26 GND RIP board Connector Pin no Signal ...

Page 407: ...D 7 MOD_CLK_R 8 GND 9 MOD_IRQ_R 10 5V 11 POR_CUHD 12 3 3V 13 3 3V 14 NC_MOD_P6 J9 1 UI_RESET_NR 2 GND 3 TX1 4 TX1 5 TX2 6 TX2 7 CLXTX 8 CLXTX 9 GND 10 5V 11 UI_RXD 12 UI_RXD 13 TX0 14 TX0 15 GND 16 5V 17 5V 18 5V 19 WAKE 20 GND 21 GND 22 AMBER_LED 23 5V_CONT 24 PWR_BUTTON RIP board Connector Pin no Signal ...

Page 408: ...3x Go Back Previous Next J11 Printhead controller board 1 GND 2 VSYN_Y 3 VSYN_M 4 VSYN_C 5 VSYN_K 6 HSYN_Y 7 HSYN_M 8 HSYN_C 9 HSYN_K 10 GND 11 LEVELY O0 12 LEVELY O1 13 LEVELY E0 14 LEVELY E1 RIP board Connector Pin no Signal ...

Page 409: ...LEVELC E0 22 LEVELC E1 23 LEVELK O0 24 LEVELK O1 25 LEVELK E0 26 LEVELK E1 27 FEED2 28 SBSY 29 GND RESRT 30 STATUS 31 FDRDY 32 CPRDY 33 STCLK 34 START 35 CBSY 36 PPRDY 37 STCLK 38 READY 39 COMMAND 40 GND J12 Printhead controller board 1 VCLK_M 2 GND 3 VCLK_Y 4 GND 5 VCLK_C 6 GND 7 VCLK_L 8 GND RIP board Connector Pin no Signal ...

Page 410: ...5 10 Service Manual 7541 03x Go Back Previous Next Printhead controller connectors ...

Page 411: ...oard Connector Connects to Pin no Signal CN1 Yellow printhead 1 HD5V 2 GND 3 HD5V 4 GND 5 HD5V 6 GND 7 HD5V 8 GND 9 HD5V 10 GND 11 HD3V 12 SO Y 13 SCK Y 14 STROBE Y 15 DATA_Y0 16 DATA_Y1 171 DATA_Y2 18 DATA_Y3 19 HSYNC Y 20 LOAD_Y 21 GND 22 CLOCK N Y 23 CLOCK P Y 24 GND ...

Page 412: ...dc 2 USB D 1 HD5V 2 GND 3 HD5V 4 GND 5 HD5V 6 GND 7 HD5V 8 GND 9 HD5V 10 GND 11 HD3V 12 SO C 13 SCK C 14 STROBE C 15 DATA_C0 16 DATA_C1 171 DATA_C2 18 DATA_C3 19 HSYNC C 20 LOAD_C 21 GND 22 CLOCK N C 23 CLOCK P C 24 GND Printhead controller board Connector Connects to Pin no Signal ...

Page 413: ...c 2 USB D 1 HD5V 2 GND 3 HD5V 4 GND 5 HD5V 6 GND 7 HD5V 8 GND 9 HD5V 10 GND 11 HD3V 12 SO M 13 SCK M 14 STROBE M 15 DATA_M0 16 DATA_M1 171 DATA_M2 18 DATA_M3 19 HSYNC M 20 LOAD_M 21 GND 22 CLOCK N M 23 CLOCK P M 24 GND Printhead controller board Connector Connects to Pin no Signal ...

Page 414: ... K 13 SCK K 14 STROBE K 15 DATA_K0 16 DATA_K1 171 DATA_K2 18 DATA_K3 19 HSYNC K 20 LOAD_K 21 GND 22 CLOCK N K 23 CLOCK P K 24 GND CN5 Engine board 1 MBUSY_IN 2 SUBRXD 3 SUBTXD 4 MOTOR_CLK1 5 MOTOR_CLK2 6 MOTOR_CLK3 7 MOTOR_CLK4 8 GND 9 HTNB1 10 PEPCNG 11 GND 12 THETALED 13 PRG_SW 14 LDPRG Printhead controller board Connector Connects to Pin no Signal ...

Page 415: ...sensors 4 GND 5 STACK_SW 6 5V CN8 Theta sensor 1 A 2 THETA 3 GND CN9 N C CN 10 CN11 HVPS 1 VCC24VFAN 2 GND 3 HV24V_2 4 HINB 5 DACLK 6 DASO 7 DARIN 8 DA_LAT CN12 N C CN13 OPTION 1 ADR0 2 ADR1 3 OPTION_RST 4 OPTION_RXD 5 OPTION_TXD 6 OPT_24V 7 OPT_24V 8 GND 9 GND 10 OPT_5V 11 GND Printhead controller board Connector Connects to Pin no Signal ...

Page 416: ...ard 5 24VSW CN16 LVPS 1 24V_GND 2 HV25V 3 SLEEP1 4 SLEEP2 5 HT1 6 HT2 7 HT3 8 ZEROCRS CN17 Toner sensor K 1 TNSETK 2 k k 3 GND 4 TSZANK 5 5V Toner sensor C 6 TNSETC 7 k k 8 GND 9 TSZANC 10 5V CN18 Toner sensor Y 1 TNSETY 2 k k 3 GND 4 TSZANY 5 5V Toner sensor M 6 TNSETM 7 k k 8 GND 9 TSZANM 10 5V Printhead controller board Connector Connects to Pin no Signal ...

Page 417: ...5 7 HTEMP6 CN20 Registration clutch 1 24VDC 2 NC 3 GND CN21 RIP board 1 VCLK Y 2 GND 3 VCLK M 4 GND 5 VCLK C 6 GND 7 VCLK K 8 GND CN22 RIP board 1 GND 2 VSYN Y 3 VSYN C 4 VSYN M 5 VSYN K 6 HSYN Y 7 HSYN C 8 HSYN M 9 HSYN K 10 GND 11 LEVELY O0 Printhead controller board Connector Connects to Pin no Signal ...

Page 418: ...ELM O0 16 LEVELM O1 17 LEVELM E0 18 LEVELM E1 19 LEVELC O0 20 LEVELC O1 21 LEVELC E0 22 LEVELC E1 23 LEVELK O0 24 LEVELK O1 25 LEVELK E0 26 LEVELK E1 27 GND 28 FEED2 29 SBSY 30 FPF 31 STATUS 32 FDRDY 33 CPRDY 34 START 35 CBSY 36 PPRDY 37 STCLK 38 READY 39 COMMAND 40 GND Printhead controller board Connector Connects to Pin no Signal ...

Page 419: ...Locations 5 19 7541 03x Go Back Previous Next Engine board connectors ...

Page 420: ...CZCNG 6 HTNB1 7 GND 8 MOTOR CLK4 9 MOTOR CLK3 10 MOTOR CLK2 11 MOTOR CLK1 12 TXD 13 RXD 14 MBUSY_IN CN3 N C CN4 Temp humidity sensor 1 Temp S 2 GND 3 Humid S 4 5V CN5 Paper size sensor Std Cassette 1 CPSIZE2 2 PCZCNG C 3 CPSIZE1 4 PCZCNG C 5 CPSIZE0 6 PCZCNG C CN6 Paper tray lift motor 1 PN2 2 PN1 CN7 Paper size sensor MPF Cassette 1 MPSIZE2 2 MPSIZE1 3 PCZCNG M 4 MPSIZE0 ...

Page 421: ...4 GND 5 BELT U D 6 LD CN10 Duplex solenoid DUPSOL GND CN12 Full sensor 1 GND 2 PFLIFTSW 3 LD PE Sensor STD tray 4 GND 5 PP EMP 6 LD PE Sensor MPF tray 7 GND 8 MPF DET 9 LD Reg sensor 10 GND 11 PRGSW 12 PRGSW5V CN13 Duplex clutch 1 DUPOUTCL 2 3 GND CN14 Exit sensor 1 GND 2 DUP INSW 3 5V CN15 Belt motor 1 1A BELT 2 1B BELT 3 2A BELT 4 2B BELT Engine board Connector Connects to Pin no Signal ...

Page 422: ...SYMOY B 3 DSYMOY A 4 DSYMOY B CN18 Motor M Motor 1 DSMMOY A 2 DSMMOY B 3 DSMMOY A 4 DSMMOY B CN19 Motor C Motor 1 DSCMOY A 2 DSCMOY B 3 DSCMOY A 4 DSCMOY B CN20 Motor K Motor 1 DSKMOY A 2 DSKMOY B 3 DSKMOY A 4 DSKMOY B CN21 Fuser fan 1 FFAN 2 FFALM 3 GND CN22 Main fan 1 CFAN 2 CFALM 3 GND CN23 Main switch 1 24V PR 2 24V PR CN24 LVPS 1 5V IN 2 5V GND 3 24V PR 4 24V GND 5 24 V Engine board Connector...

Page 423: ...Next CN25 Power supply fan 1 PSFAN 2 PSFALM 3 GND CN26 Rear fan 1 REAFAN 2 REAFALM 3 GND CN27 Remote switch 1 GND 2 P OFF CN28 MPF clutch 1 TMPCL 2 GND CN29 t MPF paper out 1 GND 2 TMFDET 3 LD1 Engine board Connector Connects to Pin no Signal ...

Page 424: ...5 24 Service Manual 7541 03x Go Back Previous Next LVPS Connectors LVPS board Connector Connects to Pin no Signal CN01 Scanner power supply 1 AC L 2 3 AC N CN02 Fuser sensor 1 COM 2 HT3 3 HT2 4 HT1 ...

Page 425: ...r board 1 ACXerox P 2 Heater3N 3 Heater2N 4 Heater1N 5 Sleep2 6 Sleep1 7 HT24 8 GND Engine board 9 FAN GND 10 FAN ARM 11 FAN CN06 Power supply fan 1 FAN 2 FAN ARM 3 FAN GND Connector Connects to Pin no Signal CN01 Power switch 1 110V or 220V in 3 GND CN02 LVPS 1 COM 3 110V or 220V out CN03 RIP board 1 5V 2 5V 3 24V 4 24V 5 GND 6 GND 7 GND 8 GND LVPS board Connector Connects to Pin no Signal ...

Page 426: ...COVER_OPEN 2 DGND 3 5V J2 FB paper size sensor 2 1 GND 2 5V 3 FBPS2 3 4 FBPS2 2 5 FBPS2 1 J3 1 GND 2 24V_RIP 3 24V_RIP 4 24V_RIP 5 GND 6 TOP_FB 7 BOOT SEL 8 5V 9 5V 10 GND 11 MDC RXD 12 13 GND 14 ADF_PAPER_INMDC_TXD 15 F_COVER_OPEN 16 GND 17 HMSEN 18 PAPER_GAP 19 GND 20 RESET_N 21 3 3V 22 GND 23 HW RESERVE 24 IC2_CLK 25 IC2 DATA 26 GND ...

Page 427: ...5 FBPS1 1 J5 1 5V 2 24VM_ADF 3 24VM_ADF 4 GND 5 GND 6 IO_BUS0 7 IO_BUS2 8 IO_BUS4 9 IO_BUS6 10 ADF_PICKUP_STEP 11 FB_ADF_STEP 12 DGND 13 I_ADF_PLUG 14 DGND 15 24VM_ADF 16 DGND 17 NC 18 IO_BUS1 19 NC 20 IO_BUS3 21 NC 22 IO_BUS5 23 ADF_PAPER_IN 24 NC 25 PAPER _GAP 26 3 3V ICC board Connector Pin no Signal ...

Page 428: ...3VM 2 3 3VM 3 GND 4 GND 5 FB_DIR 6 HM_SEN 7 GND 8 FBM_EN 9 FB_RS 10 GND 11 FB_MS2 12 FB_MS1 13 GND 14 TQ2 15 TQ1 16 24VM_CCD 17 FB_ADF_STEP 18 24VM_CCD J7 1 JTD1 2 GND 3 JTD 0 4 GND 5 JTCK 6 GND 7 RTCK 8 JTMS 9 3 3V 10 JIRST_N 11 3 3V 12 GND ICC board Connector Pin no Signal ...

Page 429: ...14_CLK_P 7 GND 8 98714_OUT2_M 9 98714_OUT2_P 10 GND 11 98714_OUT1_M 12 98714_OUT1_P 13 GND 14 98714_OUT0_M 15 98714_OUT0_P 16 GND 17 AFE_RESET 18 GND 19 98714_SDATA 20 98714_SCLK 21 98714_SEN_N 22 98714_SH_R 23 PWR_SVR 24 5V_CCD_IN 25 5V_CCD_IN 26 GND 27 24V_IN 28 24V_IN 29 LAMP_ON 30 GND ICC board Connector Pin no Signal ...

Page 430: ...0 98714_SEN_N 11 98714_SCLK 12 98714_SDATA 13 GND 14 AFE_RESET 15 GND 16 98714_OUT0_P 17 98714_OUT0_M 18 GND 19 98714_OUT1_P 20 98714_OUT1_M 21 GND 22 98714_OUT2_P 23 98714_OUT2_M 24 GND 25 98714_CLK_P 26 98714_CLK_M 27 GND 28 INCLK_P 29 INCLK M 30 GND J10 FB paper size sensor 3 1 GND 2 5V 3 FBPS3 3 4 FBPS3 2 5 FBPS3 1 ICC board Connector Pin no Signal ...

Page 431: ...ADF cover sensors 1 5V 2 COVER OPEN 3 GND 4 5V 5 PICKUP ROLLER 6 GND 7 5V 8 GAP 9 GND 10 5V 11 PAPER DET 12 GND J2 ADF scan motor 1 OUT2B 1 2 OUT1A 1 3 OUT2A 1 4 OUT1B 1 J6 ADF pick motor 1 OUT2B 2 2 OUT1A 2 3 OUT2A 2 4 OUT1B 2 J3 ADF paper width and length sensors 1 B5SEN 2 A4SEN 3 B4SEN 4 5V 5 GND 6 A3SEN 7 L1SEN ...

Page 432: ...s Next J4 ADF paper out sensor 1 5V 2 Paper out 3 GND J5 Duplex paper pass 1 5V 2 2 PASS SEN 3 GND J7 Scan sensor paper in 1 5V 2 PAPER SCAN 3 GND 4 5VD 5 PAPER IN 6 GND J8 Solenoids 1 24V 2 GND 3 24V 4 GND ADF relay card Connector Pin no Signal ...

Page 433: ...M MOTOR ON 4 24VM MOTOR ON 5 GND 6 24VM MOTOR ON 7 NC 8 GND 9 NC 10 GND 11 FB ADF STEP 12 NC 13 ADF PICKUP STEP 14 PAPER DET 15 FB IO BUS 3 16 NC 17 FB IO BUS 1 18 FB IO BUS 2 19 FB IO BUS 0 20 FB IO BUS 4 21 FB IO BUS 5 22 FB IO BUS 6 23 GND 24 PAPER GAP 25 5VD 26 GND J10 ADF clutch 1 24V 2 GND ADF relay card Connector Pin no Signal ...

Page 434: ...UICC connectors J1 N C J3 Touchscreen display 4 pin ribbon cable J5 N C J8 N C J10 Pop panel connector to RIP J12 Touchscreen display J20 N C J21 Speaker J22 USB card reader J23 Haptics motor J24 USB connection to RIP board J25 USB thumbdrive connector ...

Page 435: ...ions Option feeder layout STM L C M 1 0 1 0 Door interlock Transport Motor Paper tray lift motor Upper UL1 Interface Lower UL2 Interface Paper volume Paper full Transport Paper empty Transport Clutch Paper size detection Paper size detection Paper size detection JCN ...

Page 436: ...5 36 Service Manual 7541 03x Go Back Previous Next Option board layout ASSY NO CN120 CN101 CN107 CN301 CN103 CN108 CN105 CN106 CN121 IC103 IC100 CN102 0 CN104 IC Socket ...

Page 437: ... 4 4 10 VCC 5V 11 11 11 CGND 9 9 1 ADR0 6 6 2 ADR1 5 5 3 RST 10 10 4 TXD 7 7 5 RXD 8 8 6 VAA 24V 1 1 7 VAA 24V 2 2 8 AGND 3 3 9 AGND 4 4 10 VCC 5V 11 11 11 CGND 9 9 12 N C 1 ADR0 ADR0 1 2 ADR1 ADR1 2 3 RST RST 3 4 TXD TXD 4 5 RXD RXD 5 6 VAA SW VAA 24V 6 7 VAA SW VAA 24V 7 8 AGND AGND 8 9 AGND AGND 9 10 VCC 5V VCC 5V 10 11 CGND CGND 11 12 OPEN_DET_H VAA SW 1 13 CENTA_DET_L CGND 2 14 VAA SW N C 㩎㩨㨻...

Page 438: ...5 38 Service Manual 7541 03x Go Back Previous Next ...

Page 439: ...bricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubr...

Page 440: ...6 2 Service Manual 7541 03x Go Back Previous Next ...

Page 441: ...its option Refers to the number of units in a particular option It does not include the rest of the base machine Units FRU 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 ...

Page 442: ...7 2 Service Manual 7541 03x Go Back Previous Next Assembly 1 Covers ...

Page 443: ...ver 15 40X6124 1 1 Access cover 16 40X6369 1 1 Option cable 17 40X6125 1 1 Option cover 18 40X6298 1 1 Back cover 19 40X6297 1 1 Cable cover 20 40X6296 Printer top cover 21 40X6743 1 1 Op panel paper exit guide 22 40X6417 1 1 Output bin full lever 23 40X6273 1 1 B S link arm spring 24 40X6269 1 1 B S link arm 25 40X6270 1 1 Safety switch spring 26 40X6267 1 1 Release link 27 40X6271 1 1 Release sp...

Page 444: ...7 4 Service Manual 7541 03x Go Back Previous Next Assembly 2 Flatbed and ADF ...

Page 445: ...Parts catalog 7 5 7541 03x Go Back Previous Next Assembly 2 Flatbed and ADF Asm index Part number Units mach Units FRU Description 2 1 40X6545 1 1 ADF unit whole unit 2 40X6980 1 1 Flatbed whole unit ...

Page 446: ...7 6 Service Manual 7541 03x Go Back Previous Next Assembly 3 Flatbed ...

Page 447: ...kit 7 40X6957 1 1 Button assembly op panel top 8 40X6959 1 1 Op panel access cover 9 40X6958 1 1 Op panel bottom 10 40X6978 1 1 Flatbed front cover 11 40X6443 1 1 Model name cover 12 40X6326 1 1 CCD belt 13 40X6548 3 1 Optical paper size sensors 14 40X6325 1 1 Flatbed cover open sensor NS 40X6977 1 1 Op panel light pipe NS 40X6757 4 1 Scanner rubber pad NS 40X6758 4 1 Scanner stopper screw NS 40X6...

Page 448: ...7 8 Service Manual 7541 03x Go Back Previous Next Assembly 4 ADF 1 ...

Page 449: ...5 40X6346 1 1 Upper flatbed top cover 6 40X6344 1 1 Right ADF cover 7 40X6334 1 1 Flatbed hinge 8 40X6347 1 1 Lower flatbed top cover 9 40X6432 1 1 Flatbed cushion 10 40X6333 1 1 ADF hinge 11 40X6329 1 1 ADF relay card 12 40X6433 1 1 ADF cable 13 40X6342 1 1 ADF relay card cover 14 40X6343 1 1 Left ADF cover 15 40X6542 1 1 Release arm 16 40X6544 1 1 Idle clutch roller 17 40X6543 1 1 Idle pulley ro...

Page 450: ...7 10 Service Manual 7541 03x Go Back Previous Next Assembly 5 ADF 2 ...

Page 451: ...de 11 40X6976 1 1 Duplex timing sensor 12 40X6532 1 1 Gear w spring holder 13 40X6538 1 1 Spur G28T gear 14 40X6537 1 1 Spur G63 27T gear 15 40X6536 1 1 Spur G36T gear 16 40X6974 1 1 Duplex out sensor actuator 17 40X6975 1 1 Duplex out sensor 18 40X6534 1 1 Scan sensor w paper in sensor 19 40X6535 1 1 Scan sensor actuator 20 40X6348 1 1 ADF main feeder 21 40X6335 1 1 ADF drive clutch 22 40X6434 1 ...

Page 452: ...7 12 Service Manual 7541 03x Go Back Previous Next Assembly 6 Duplex components 1 ...

Page 453: ...te 11 40X6148 1 1 Duplex ground plate 12 40X6260 1 1 Duplex static brush 13 40X6159 1 1 F2 S Transfer spring 14 40X6143 1 Transfer roll bushing 15 40X6151 2 1 Roller guide spring 16 40X6258 1 1 Roller guide 17 40X6012 1 1 Transfer roll 18 40X1104 8 1 Photo sensor 19 40X6158 1 1 Duplex clutch cable 20 40X6150 1 1 2 S Transfer spring 21 40X6149 1 1 Transfer contact plate 22 40X6259 1 1 Duplex ground...

Page 454: ...7 14 Service Manual 7541 03x Go Back Previous Next Assembly 7 Duplex components 2 ...

Page 455: ...F catch 7 40X6141 1 1 Sub tray 8 40X6136 1 1 A S pushing spring 9 40X6137 4 1 Duplex cover roller 10 40X6135 1 1 B S pushing spring 11 40X6134 1 1 Right cover 12 40X6133 1 1 Safety spring 13 40X6127 1 1 Safety switch rod 14 40X6128 2 1 Door lever lock 15 40X6131 1 1 Lever open spring 16 40X6130 1 1 Lever shaft 17 40X6129 1 1 Door lever 18 40X6132 1 1 Lever guide 19 40X6983 2 1 Duplex cover pin 20 ...

Page 456: ...7 16 Service Manual 7541 03x Go Back Previous Next Assembly 8 Paper exit ...

Page 457: ...o Back Previous Next Assembly 8 Paper exit Asm index Part number Units mach Units FRU Description 1 40X6579 1 1 Paper exit roller 2 40X1104 8 1 Photo sensor exit sensor 3 40X6168 1 1 Exit sensor cable 4 40X6745 1 1 Paper exit guide ...

Page 458: ...7 18 Service Manual 7541 03x Go Back Previous Next Assembly 9 Base 1 ...

Page 459: ...number Units mach Units FRU Description 1 40X6173 1 1 Main unit drive 2 40X6261 1 1 Photo interrupter cable 3 40X1104 8 1 Photo sensor 4 40X6160 1 1 Sub frame 5 40X6162 1 1 Belt motor 6 40X6262 1 1 Belt motor cable 7 40X6161 4 1 Drive unit motor NS 40X7052 1 1 Base 1 screw parts pack ...

Page 460: ...7 20 Service Manual 7541 03x Go Back Previous Next Assembly 10 Base 2 ...

Page 461: ... 1 Exit solenoid bracket 5 40X6165 1 1 Exit drive unit solenoid 6 40X6368 Engine power supply Door interlock cable 7 40X6166 1 1 Door open switch 8 40X1104 8 1 Photo sensor 9 40X6278 1 1 Fuser exit sensor cable 10 40X6367 1 1 Engine paperfeed cable Paper exit unit 11 40X6164 1 1 Exit drive unit motor 12 40X6209 1 1 Tray lift motor cable 13 40X6172 1 1 Paper tray lift motor NS 40X7442 1 1 Base 2 sc...

Page 462: ...7 22 Service Manual 7541 03x Go Back Previous Next Assembly 11 Base 3 ...

Page 463: ...ts catalog 7 23 7541 03x Go Back Previous Next Assembly 11 Base 3 Asm index Part number Units mach Units FRU Description 1 40X6174 2 1 Handle cover 2 40X6175 4 1 Bottom foot NS 40X6421 2 1 Rubber grip pad ...

Page 464: ...7 24 Service Manual 7541 03x Go Back Previous Next Assembly 12 Paper feed 19 21 22 24 25 20 23 19 22 22 22 19 ...

Page 465: ...1 Registration gear 10 40X6183 1 1 Lower registration spring 11 40X6184 1 1 Upper registration spring 12 40X6179 2 1 Feed roll 13 40X6177 2 1 Feed roll gear 14 40X6178 2 1 Pickup gear 15 40X6180 2 1 Pick roll 16 40X6186 2 1 Separator roll 17 40X6187 2 1 Torque limiter 18 40X6181 2 1 Pickup lever A 19 40X6190 1 1 Registration sensor cable 20 40X6422 1 1 Upper registration spring 21 40X6423 1 1 Lowe...

Page 466: ...7 26 Service Manual 7541 03x Go Back Previous Next Assembly 13 Electrical 1 ...

Page 467: ...ly 13 40X6751 1 1 220V Scanner power supply 14 40X6749 1 1 Main power cable 15 40X6263 1 1 Sensor A S cleaner 16 40X6266 1 1 Sensor cover 17 40X6265 1 1 Sensor cover spring 18 40X6199 1 1 Density sensor 19 40X6201 1 1 Density sensor cable 20 40X6202 1 1 Humidity sensor 21 40X6203 1 1 Humidity sensor cable 22 40X6428 3 1 Paper size sensors 23 40X6206 1 1 Main fan 24 40X6205 1 1 Power supply fan 25 ...

Page 468: ...7 28 Service Manual 7541 03x Go Back Previous Next Assembly 14 Electrical 2 ...

Page 469: ...clutch 10 40X6416 1 1 MPF Engine board cable 11 40X6190 1 1 Registration sensor cable 12 40X6748 1 1 RIP Harness cable 13 40X6261 1 1 Photo interrupter cable Belt up down 14 40X6194 1 1 Paperfeed clutch cable 15 40X6165 1 1 Exit solenoid cable w solenoid 16 40X6209 1 1 Tray lift motor cable 17 40X6171 1 1 Fuser fan cable fan included 18 40X6367 1 1 Engine paperfeed cable 19 40X6161 1 1 Drive unit ...

Page 470: ...7 30 Service Manual 7541 03x Go Back Previous Next Assembly 15 Upper assembly ...

Page 471: ... mach Units FRU Description 1 40X6429 4 1 LED printhead assembly 2 40X6216 4 1 LED FFC ribbon cable 3 40X6218 4 1 LED printhead 4 40X6756 1 1 Printhead controller board 5 40X6215 8 1 Contact spring 6 40X6214 2 1 Toner sensor NS 40X6369 1 1 PRCONT option cable NS 40X7449 1 1 Upper assembly screw parts pack ...

Page 472: ...7 32 Service Manual 7541 03x Go Back Previous Next Assembly 16 Printhead controller board cables ...

Page 473: ... Fuser power cable 110V 2 40X6440 1 1 Fuser power cable 220V 3 40X6168 1 1 Paper exit sensor cable 4 40X6278 1 1 Fuser exit sensor cable 5 40X6756 1 1 Printhead controller board 6 40X6201 1 1 Density sensor cable 7 40X6198 1 1 Theta sensor cable 8 40X6210 1 1 Power supply fan cable 9 40X6370 1 1 RIP print controller cable 10 40X6369 1 1 Printhead controller option cable 11 40X6748 1 1 RIP harness ...

Page 474: ...7 34 Service Manual 7541 03x Go Back Previous Next Assembly 17 Paper trays ...

Page 475: ...ext Assembly 17 Paper trays Asm index Part number Units mach Units FRU Description 1 40X6223 1 1 Multipurpose tray 2 40X6219 1 1 Main paper tray NS 40X6220 1 1 Tray rack gear NS 40X6221 1 1 Tray pinion gear NS 40X7451 1 1 Cassette screw parts pack ...

Page 476: ...7 36 Service Manual 7541 03x Go Back Previous Next Assembly 18 Fuser ...

Page 477: ...Parts catalog 7 37 7541 03x Go Back Previous Next Assembly 18 Fuser Asm index Part number Units mach Units FRU Description 1 40X6013 1 1 110V Fuser 1 40X6093 1 1 220V Fuser ...

Page 478: ...7 38 Service Manual 7541 03x Go Back Previous Next Assembly 19 550 sheet option feeder covers ...

Page 479: ...X6251 1 1 Right front option cover 4 40X6252 1 1 Right rear option cover 5 40X6254 1 1 Right switch cover 6 40X6224 1 1 Stand base foot 7 40X6250 1 1 Left option cover 8 40X6248 1 1 Rear option cover 9 40X6249 1 1 Rear connector cover 10 40X6255 1 1 Upper front option cover 11 40X6253 1 1 Right middle option cover NS 40X1173 1 1 Photo interrupter Horizontal sensor NS 40X7452 1 1 550 sheet paperfee...

Page 480: ...7 40 Service Manual 7541 03x Go Back Previous Next Assembly 20 550 sheet option feeder base ...

Page 481: ...6362 1 1 UL2 Interface cable 3 40X6430 3 1 Option switch sensor 4 40X6358 1 1 Rising unit hub 5 40X6359 1 1 Rising unit spring 6 40X6360 1 1 Timing belt 7 40X6231 1 1 Option interface board 8 40X6232 1 1 Main interface cable 9 40X6233 1 1 Stepper motor cable 10 40X6230 1 1 Option stepper motor 11 40X6229 1 1 Opt tray paper lift motor NS 40X7452 1 1 550 sheet paperfeed screw parts pack ...

Page 482: ...7 42 Service Manual 7541 03x Go Back Previous Next Assembly 21 550 sheet option feeder paper feed ...

Page 483: ...d roll 4 40X1173 1 1 Horizontal sensor paperfeed 5 40X1106 1 1 Retainer clip 6 40X1078 1 1 Option tray feed roll 7 40X1077 1 1 Option tray pick roll 8 40X1079 1 1 Option tray separator roll 9 40X1080 1 1 Torque limiter clutch 10 40X6235 1 1 Timing belt S 11 40X6237 1 1 Timing belt L 12 40X6234 1 1 Opt tray door closed sensor 13 40X6232 1 1 Main interface cable 14 40X6236 1 1 Option paperfeed clutc...

Page 484: ...7 44 Service Manual 7541 03x Go Back Previous Next Assembly 22 550 sheet option feeder tray ...

Page 485: ...Parts catalog 7 45 7541 03x Go Back Previous Next Assembly 22 550 sheet option feeder tray Asm index Part number Units mach Units FRU Description 1 40X6246 1 1 Option paper tray ...

Page 486: ...1g server RW NS 40X6337 1 Arabic font card NS 40X5969 1 Korean font card NS 40X5970 1 Simplified Chinese font card NS 40X5971 1 Traditional Chinese font card NS 40X5972 1 Japanese font card NS 40X6924 1 Forms and barcode card NS 40X6925 1 IPDS SCS card NS 40X6928 1 Prescribe card NS 40X0271 1 UK straight power cord NS 40X0301 1 Australia 8ft straight power cord NS 40X3609 1 Japan power cord NS 40X...

Page 487: ... Min Copy Memory 3 13 NumPad Job Assist 3 13 Configuration menu USB Scan to Local 3 11 configuration menu 3 9 accessing 3 7 Auto Align Adj 3 13 Black Only Mode 3 11 Color Alignment 3 14 Color Trapping 3 11 Demo Mode 3 12 Disk Encryption 3 15 Download Emuls 3 12 Energy Conserve 3 13 entering 3 9 Envelope Prompts 3 14 Exit Config Menu 3 17 Factory Defaults 3 12 Font Sharpening 3 15 Jobs On Disk 3 15...

Page 488: ...6 exiting configuration menu 3 17 F Factory Defaults 3 12 false door open service check 2 90 Fax dials a number but no connection is made 2 87 Fax reception fails 2 84 Fax Storage Location 3 13 Faxes fail to transmit 2 82 Feed Test SCANNER 3 28 flash options service check 2 94 Flash Test 3 24 flatbed lock 2 35 Font Sharpening 3 15 Format Fax Storage 3 13 Fuser entry sensor removal 4 91 Fuser exit ...

Page 489: ...F size service check 2 100 Paper is being picked up and carried to the registration roller Paper jams 200 250 24x 2 24 paper jam 200 2 18 201 2 18 203 2 19 230 2 20 231 39 2 21 24x 2 22 250 2 23 Clearing and troubleshooting paper jams 2 18 Paper level sensor removal 4 204 Paper path service checks 2 24 Paper Prompts 3 14 paper size sensor removal 4 42 Paper size switch removal 4 105 Paper size swi...

Page 490: ...0 transfer belt position sensor removal 4 41 Transport sensor removal 4 204 Tray lift motor removal 4 207 Upper and lower registration springs removal 4 186 Waste toner sensor removal 4 112 removals Back cave cover 4 18 Cord cover 4 6 Crossbar removal not a FRU 4 74 Drive unit 4 79 Drive unit motor C M Y K 4 83 Front op panel cover 4 11 Fuser removal 4 61 Inner right cover 4 19 Left EMI shield rem...

Page 491: ...ed to the registration roller Paper jams 200 250 24x 2 24 paper path 2 24 Paper has entered the duplex unit Paper jam 230 231 9 2 26 Paper has entered the fuser and exited the printer Paper jam 203 2 25 Paper has exited the registration roller and entered the fuser Paper jam 201 2 25 Paper has stopped at the registration roller or has not reached the fuser Paper jams 200 250 24x 2 25 Paper is bein...

Page 492: ...pper motor removal 4 206 Sub drive unit removal 4 84 Sub frame unit removal 4 104 T Temperature and humidity sensor removal 4 101 Theory of operation Color theory 3 47 Printer engine 3 29 Scanner 3 44 Theta sensor removal 4 56 Toner sensor removal 4 97 tools required 1 15 Torque limiter removal 4 186 Transfer belt CRU removal 4 40 Transfer belt motor removal 4 100 transfer belt position sensor rem...

Page 493: ...e 7 33 40X6198 Theta sensor cable 7 27 40X6199 Density sensor 7 27 40X6201 Density sensor cable 7 33 40X6201 Density sensor cable 7 27 40X6202 Humidity sensor 7 27 40X6203 Humidity sensor cable 7 27 40X6204 110 V Low voltage power supply 7 27 40X6205 Power supply fan 7 27 40X6206 Main fan 7 27 40X6208 High volt power supply cable 7 27 40X6209 Tray lift motor cable 7 21 40X6210 Power supply cable 7...

Page 494: ... 40X6327 ADF pick roll assembly 7 11 40X6328 ADF separator roll 7 11 40X6329 ADF relay card 7 9 40X6330 ADF motor frame w motors 7 11 40X6331 Outer ADF top cover 7 11 40X6332 Inner ADF top cover 7 11 40X6333 ADF hinge 7 9 40X6334 Flatbed hinge 7 9 40X6335 ADF drive clutch 7 11 40X6336 Roller bearing 7 11 40X6338 ADF input tray 7 9 40X6340 Top cover release handle 7 11 40X6341 Top cover release hoo...

Page 495: ...ess cable 7 33 40X6748 RIP harness cable 7 27 40X6749 Main power cable 7 29 40X6749 Main power cable 7 27 40X6750 110V Scanner power supply 7 27 40X6751 220V Scanner power supply 7 27 40X6752 RIP power supply cable 7 27 40X6753 MPSP cable scanner low volt power supply 7 27 40X6755 MFP cave light assembly 7 3 40X6757 Scanner rubber pad 7 7 40X6758 Scanner stopper screw 7 7 40X6759 Scanner sub rubbe...

Page 496: ... Cassette screw parts pack 40X7451 7 35 Chile Uraguay powercord 40X0273 7 46 Complete duplex 40X6126 7 3 Contact spring 40X6215 7 31 Cover 1 screw parts pack 40X6499 7 3 7 13 7 15 Cover closed actuator cable 40X7455 7 29 D Discharge brush plate 40X6277 7 13 Door lever 40X6129 7 15 Door lever lock 40X6128 7 15 Door open switch 40X6166 7 21 Drive gear 40X6146 7 13 Drive unit motor 40X6161 7 19 drive...

Page 497: ...X5969 7 46 L LED FFC cable 40X6216 7 31 LED printhead 40X6218 7 31 LED printhead assembly 40X6429 7 31 Left cover 40X6122 7 3 Left hinge 40X6283 7 3 Lever guide 40X6132 7 15 Lever open spring 40X6131 7 15 Lever shaft 40X6130 7 15 Lower registration spring 40X6183 7 25 Lower registration spring 40X6423 7 25 M Main Standard paper tray 40X6219 7 35 Main drive unit 40X6173 7 19 main fan 40X6206 7 29 M...

Page 498: ... paper size switch cable 40X6120 7 29 Paper tray lift motor 40X6172 7 21 Paper tray size switch cable 40X7456 7 29 Paperfeed clutch 40X6191 7 25 Paperfeed clutch cable 40X6194 7 25 Paperfeed maintenance kit 40X6372 7 25 Paperfeed screw parts pack 40X7447 7 25 Paperfeed unit 40X6176 7 25 Paperfeed unit motor 40X6192 7 25 Parallel 1284 B serial adapter 40X4823 7 46 Photo interrupter cable 40X6261 7 ...

Page 499: ...7 41 Sub drive unit 40X6163 7 21 Sub frame 40X6160 7 19 Sub tray 40X6141 7 15 Switzerland powercord 40X1772 7 46 T Taiwan powercord 40X1791 7 46 Timing belt 40X6235 7 43 Timing belt 40X6360 7 41 Timing belt L 40X6237 7 43 Toner sensorl 40X6214 7 31 Torque limiter 40X6187 7 25 Torque limiter clutch 40X1080 7 43 Traditional Chinese font card 40X5971 7 46 Transfer belt door DS lock 40X6169 7 3 Transf...

Page 500: ...I 14 Service Manual 7541 03x ...

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