PRINTER

e-STUDIO450S e-STUDIO500S

12G9662

Edition: April 11, 2007 The following paragraph does not apply to any country where such provisions are inconsistent with local law: TOSHIBA PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time.

2007 TOSHIBA TABS, INC. All rights reserved. UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense. P/N 12G9662

Table of contents
Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Configured models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Data streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Recommended operating clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Power requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Paper and specialty media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Supported print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Print media sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Print media types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Print media weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Selecting print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Paper characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Transparencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Card stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Storing print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Avoiding jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

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

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Service errors (8xx.xx and 9xx.xxs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 User status and attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Additional information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Understanding the MFP operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 MFP operator panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Home screen and Home screen buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Buttons and touchscreen icon buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Printer symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 ScannerADF symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Scannerflatbed symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Table of contents

iii

Scannerscan quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 High-capacity feeder (2000-sheet) symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 Paper tray symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Duplex option symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Envelope feeder symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Messages and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Sub error codes for 8xx, 9xx, and 2xx error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 User status displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38 User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 User line 2 link messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Check device connection messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 User attendance messagespaper jams and paper handling errors (2xx.xx) . . . . . . . . . . . . . . . . . . 2-57 Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95 202.03 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95 202.06 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95 290.00 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-96 290.01 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-98 290.02 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 290.10 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102 291.00 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104 291.01 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 291.02 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 292.00 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107 293 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 294.00 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 294.01 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 294.02 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112 294.03 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113 298.01 Error code service checkmodel 500S - - - - - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-115 298.02 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115 842.xx Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115 843.xx Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 845.00 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117 848.00 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 848.01 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 900.xx Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 900.90 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 927.xx Fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119 Main fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119 Cartridge fan service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119 950.00 through 950.29 EPROM mismatch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 950.30 through 950.60 EPROM mismatch failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121 ADF paper length sensor service checkmodel 500S - - - - - - - . . . . . . . . . . . . . . . . . . . . . . . . . .2-122 ADF paper width sensor service checkmodel 500S - - - - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123 Charge roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-123 Cover closed sensors service checkflatbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-124 Cover closed switch/cable service checkprinter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125 Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125 Duplex option service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-127 Envelope feeder service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 Flatbed size sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-131 Fuser service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132 920.xxCold fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132 922.xxCold fuser check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134 923.xxHot fuser service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-135 924.xxHot fuser service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136 925.xxHot fuser service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137

iv Service Manual

Fuser exit sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser narrow media sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High-capacity feeder input tray service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input tray(s) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD touchscreen contrast control service checkmodel 450S . . . . . . . . . . . . . . . . . . . . . . . . . . LCD touchscreen display service checkmodel 500S - - - - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . Main drive service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator panel Help and Home buttons service checkmodel 450S - . . . . . . . . . . . . . . . . . . . . . Operator panel Menu button service checkmodel 450S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator panel right cover assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flash memory option(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRAM memory option(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hard disk option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output bin sensor standard tray service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper feed service checkprinter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper size sensing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel port service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scan quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signature button assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System board service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Toner sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-138 2-139 2-141 2-146 2-147 2-148 2-149 2-149 2-153 2-154 2-154 2-154 2-155 2-155 2-155 2-155 2-156 2-156 2-158 2-159 2-160 2-165 2-170 2-170 2-171 2-172

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

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Entering Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Registration (printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 PRINT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Input source tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Printing Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 HARDWARE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Button Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 DRAM Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 CACHE Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Parallel Wrap test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Serial Wrap test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 DUPLEX TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Quick Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Top Margin (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Sensor Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Motor Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Duplex Feed 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Duplex Feed 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 INPUT TRAY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Feed Tests (input tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Sensor Test (input tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 OUTPUT BIN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Feed Tests (output bins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Sensor Test (standard output bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 BASE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Table of contents

DEVICE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 PRINTER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Printed Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Permanent Page Count. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Envelope Enhance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 Engine Setting 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Edge to Edge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Parallel strobe adjustment (Par x Strobe Adj) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19 EP SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Fuser Temperature (Fuser Temp). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Fuser Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Warm Up Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20 Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Print Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Charge Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Gap Adjust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Clear Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 SCANNER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 ASIC Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23 Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23 Scanner Manual Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Configuration menu (CONFIG MENU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Available menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Maintenance Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Reset Maintenance Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25 Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 SIZE SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 Min Copy Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Format Fax Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 ADF Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 FB Edge Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 Automatic Scanner Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30 EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31 Envelope Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Jobs On Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Disk Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Wipe Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Require Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 LES Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

vi Service Manual

Key Repeat Initial Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Repeat Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiper Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exit Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autocompensator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Autoconnect system, paper tray options, envelope feederelectrical . . . . . . . . . . . . . . . . . . . . . . . Autoconnect cabling and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duplex Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Option microcode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper feed jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identifying jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access doors and trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearing jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Paper Jam Check MP Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Paper Jam Check Env Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23x and 24x jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 and 201 Paper Jam Remove Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Paper Jam Open Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23x Paper Jam Open Duplex Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearing ADF jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290, 291, 292, and 294 Scanner Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-35 3-35 3-35 3-35 3-36 3-36 3-37 3-37 3-37 3-37 3-38 3-38 3-39 3-40 3-40 3-40 3-41 3-43 3-46 3-47 3-48 3-49 3-49

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

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Adjustment procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Fuser solenoid adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Printhead assembly adjustmentprinter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Paper alignment assembly adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Scanner registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Automatic Scanner Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Manual registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Scanner ADF and flatbed removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 ADF front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 ADF pick assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 ADF rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 ADF top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Scanner left side cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Front flatbed cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Scan cover (flatbed) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Scanner right side cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 ADF attach screws removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 ADF CCD module assembly removal (model 500S) . - - - - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 ADF complete assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 ADF upper entrance guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 CCD belt removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 CCD belt tension spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Cover closing actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Cover closed actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Document tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Flatbed CCD ribbon cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Flatbed CCD module assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Flatbed contact glass removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Flatbed white cushion removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Table of contents

vii

Flatbed interconnect card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33 Flatbed paper length sensor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Flatbed scan assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Flatbed scan motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Hard disk removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Home sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 Lower exit guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47 Pickup solenoid assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48 Scanner control card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 Scanner flatbed glass holder assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 Separator assembly torque limiter removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 Upper glass holder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53 Printer removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54 Fuser wiper cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 Upper sub cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55 Upper tray cover removal (paper support) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 Printer left side cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 Redrive door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 Printer right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 Operator panel left cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61 Operator panel right cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64 Touchscreen bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66 LCD touchscreen removalmodel 500S - - - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67 LCD touchscreen removalmodel 450S - - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 4-69 Multipurpose feeder/lower front cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-71 Left cover handle holder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72 Right cover handle holder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72 Left and right frame extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73 Pass thru plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-74 Bevel gear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75 Developer drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-77 Developer drive coupler kit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-78 ESD cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78 Fuser assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79 Fuser exit sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82 Fuser exit sensor flag and spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83 Fuser lamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86 Fuser narrow media sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88 Fuser narrow media flag and spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90 Fuser to LVPS AC cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92 Fuser top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95 Fuser transfer plate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-97 Gear release link removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-98 High voltage power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99 Inner paper deflector assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101 Input sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102 Integrated tray autocompensator assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-103 Integrated tray autocompensator pick roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105 Interface card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107 LCD inverter card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108 Low voltage power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-109 Main fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-111 Main drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-113 Modem removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115 MPF arm assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-116 MPF lower paper deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117 MPF pick tire removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-118 MPF solenoid assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119

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Paper alignment assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper bin full sensor flag removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper size sensing board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power takeoff shaft and spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer outer shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redrive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signature button contact assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System board and inner shield removalmodel 450S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System board and inner shield removal model 500S . . . . . - - - - - - . . . . . . . . . . . . . . . . . . . . . Toner sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper cover removal (printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper front cover hinge assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper paper deflector assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USB card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-122 4-124 4-125 4-126 4-126 4-127 4-128 4-129 4-130 4-131 4-132 4-132 4-133 4-136 4-138 4-139

Locations and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Sensorsflatbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 SensorsADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 System board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Autoconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Fuser board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 High voltage power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Interface card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 USB card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Low voltage power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Operator panel card (UICC #1)model 450S - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Operator panel card (UICC #1)model 500S . . . . . . . . . . . . . . . . . . . . . . - - - - - - - -. . . . . . . . . . . . 5-14 LCD inverter board (IUCC #2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Scanner control card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Motor driver board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Flatbed interconnect card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Modem card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

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

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the scanner glass, cushions, and strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-1 6-1 6-2

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

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Assembly 1: Coversprinter (model450S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Assembly 2: Coverprinter (models 500S) . . . . - - - - - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Assembly 3: CoversADF scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Assembly 4: Frame 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Assembly 5: Frame 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Assembly 6: Frame 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Assembly 7: Scanner automatic document feeder (ADF)pickup . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Assembly 8: Scanner ADFpaper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Table of contents

ix

Assembly 9: Scanner ADFlower exit guide assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 10: Scanner ADFmotors and belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 11: Scanner ADFsensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 12: Scannerflatbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 13: Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 14: Paper feedautocompensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 15: Paper feedmultipurpose feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 16: Paper feedalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 17: Integrated 500-sheet paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 18: DrivesMain drive and developer drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 19: Hot roll fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 20: Transfer/charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 21: Electronicspower supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 22: Electronicscard assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 23: Electronicsshields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 24: Cabling diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 25: Cabling diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 26: Cabling diagram 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 27: Cabling diagram 4model 450S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 28: Cabling diagram 4model 500S ................................. Assembly 29: Cabling diagram 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 30: Cabling diagram 6model 450S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 31: Cabling diagram 6model 500S ................................. Assembly 32: Cabling diagram 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 33: Cabling diagram 8model 450S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 34: Cabling diagram 8model 500S ................................. Assembly 35: Optional 250-sheet paper drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 36: Optional 250-sheet paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 37: Optional 500-sheet paper drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 38: Optional 500-sheet paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 39: Duplex option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 40: Envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 41: High-capacity feeder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 42: High-capacity feeder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 43: High-capacity feeder 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 44: High-capacity feeder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 45: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-18 7-19 7-20 7-22 7-24 7-25 7-26 7-28 7-30 7-32 7-34 7-36 7-38 7-40 7-42 7-43 7-44 7-45 7-46 7-48 7-50 7-52 7-54 7-56 7-57 7-58 7-59 7-60 7-61 7-62 7-63 7-64 7-66 7-68 7-69 7-70 7-71

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1 Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-9

x Service Manual

Laser notices
A laser notice label may be affixed to this MFP.

Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1. Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers. The laser system and printer are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.

Laser
Der Drucker erfllt gem amtlicher Besttigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J fr Laserprodukte der Klasse I (1). In anderen Lndern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825-1 gem amtlicher Besttigung erfllt. Laserprodukte der Klasse I gelten als unschdlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Lnge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, da im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I bersteigen wrde, Menschen keinesfalls erreicht.

Avis relatif lutilisation de laser

Pour les Etats-Unis : cette imprimante est certifie conforme aux provisions DHHS 21 CFR alina J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante rpond aux normes IEC 60825-1 relatives aux produits laser de Classe I. Les produits laser de Classe I sont considrs comme des produits non dangereux. Cette imprimante est quipe dun laser de Classe IIIb (3b) (arsniure de gallium dune puissance nominale de 5 milliwatts) mettant sur des longueurs donde comprises entre 770 et 795 nanomtres. Limprimante et son systme laser sont conus pour impossible, dans des conditions normales dutilisation, dentretien par lutilisateur ou de rvision, lexposition des rayonnements laser suprieurs des rayonnements de Classe I .

Laser notices

xi

Avvertenze sui prodotti laser

Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1. I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) allarseniuro di gallio della potenza di 5mW che opera sulla lunghezza donda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

Avisos sobre el lser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos lser de Clase I (1) establecidos en el subcaptulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los dems pases, rene todas las condiciones expuestas en la norma IEC 60825-1 para productos lser de Clase I (1). Los productos lser de Clase I no se consideran peligrosos. La impresora contiene en su interior un lser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanmetros. El sistema lser y la impresora estn diseados de forma que ninguna persona pueda verse afectada por ningn tipo de radiacin lser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situacin de servicio tcnico.

Declarao sobre Laser

A impressora est certificada nos E.U.A. em conformidade com os requisitos da regulamentao DHHS 21 CFR Subcaptulo J para a Classe I (1) de produtos laser. Em outros locais, est certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1. Os produtos laser da Classe I no so considerados perigosos. Internamente, a impressora contm um produto laser da Classe IIIb (3b), designado laser de arseneto de potssio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanmetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiao laser superior a um nvel de Classe I durante a operao normal, a manuteno feita pelo utilizador ou condies de assistncia prescritas.

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Service Manual

Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1.

Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder p blgelngdeomrdet 770-795 nanometer. Lasersystemet og printeren er udformet sledes, at mennesker aldrig udsttes for en laserstrling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

Huomautus laserlaitteesta
Tm kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -mrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -mrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia kyttjlle. Kirjoittimessa on sisinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometri. Laserjrjestelm ja kirjoitin on suunniteltu siten, ett kyttj ei altistu luokan I mrityksi voimakkaammalle steilylle kirjoittimen normaalin toiminnan, kyttjn tekemien huoltotoimien tai muiden huoltotoimien yhteydess.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttmlle lasersteilylle. l katso steeseen. VARNING! Osynlig laserstrlning nr denna del r ppnad och sprren r urkopplad. Betrakta ej strlen.

Laser notices

xiii

Laser-notis
Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J fr laserprodukter av Klass I (1). I andra lnder uppfyller skrivaren kraven fr laserprodukter av Klass I enligt kraven i IEC 60825-1. Laserprodukter i Klass I anses ej hlsovdliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som bestr av en laserenhet av gallium-arsenid p 5 milliwatt som arbetar i vglngdsomrdet 770-795 nanometer. Lasersystemet och skrivaren r utformade s att det aldrig finns risk fr att ngon person utstts fr laserstrlning ver Klass I-niv vid normal anvndning, underhll som utfrs av anvndaren eller annan freskriven servicetgrd.

Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1. Klasse I-laserprodukter er ikke betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som bestr av en gallium-arsenlaserenhet som avgir strling i blgelengdeomrdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstrling ut over klasse I-niv under vanlig bruk, vedlikehold som utfres av brukeren, eller foreskrevne serviceoperasjoner.

Avs sobre el Lser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes lser de classe I (1), i segons ha estat certificat en altres llocs, s un producte lser de classe I que compleix els requisits dIEC 60825-1. Els productes lser de classe I no es consideren perillosos. Aquesta impressora cont un lser de classe IIIb (3b) darsenir de gal.li, nominalment de 5 mil.liwats, i funciona a la regi de longitud dona de 770-795 nanmetres. El sistema lser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci lser per sobre dun nivell de classe I durant una operaci normal, durant les tasques de manteniment dusuari ni durant els serveis que satisfacin les condicions prescrites.

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Service Manual

Japanese Laser Notice

Laser notices

xv

Korean Laser Notice

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Service Manual

Safety information
The safety of this product is based on testing and approvals of the original design and specific
components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions. CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.

Consignes de scurit
La scurit de ce produit repose sur des tests et des
agrations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilit concernant la scurit en cas d'utilisation de pices de rechange non agres. Les consignes d'entretien et de rparation de ce produit s'adressent uniquement un personnel de maintenance qualifi. Le dmontage et l'entretien de ce produit pouvant prsenter certains risques lectriques, le personnel d'entretien qualifi devra prendre toutes les prcautions ncessaires. ATTENTION : Ce symbole indique la prsence d'une tension dangereuse dans la partie du produit sur laquelle vous travaillez. Dbranchez le produit avant de commencer ou faites preuve de vigilance si l'excution de la tche exige que le produit reste sous tension.

Norme di sicurezza
La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti
specifici. Il produttore non responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona pi elevato. Il personale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie. ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto. Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.

-xvii

Sicherheitshinweise
Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprnglichen Modells und
bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung fr die Sicherheit bernommen. Die Wartungsinformationen fr dieses Produkt sind ausschlielich fr die Verwendung durch einen Wartungsfachmann bestimmt. Whrend des Auseinandernehmens und der Wartung des Gerts besteht ein zustzliches Risiko eines elektrischen Schlags und krperlicher Verletzung. Das zustndige Fachpersonal sollte entsprechende Vorsichtsmanahmen treffen. ACHTUNG: Dieses Symbol weist auf eine gefhrliche elektrische Spannung hin, die in diesem Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gert den Netzstecker des Gerts, bzw. arbeiten Sie mit groer Vorsicht, wenn das Produkt fr die Ausfhrung der Arbeiten an den Strom angeschlossen sein mu.

Pautas de Seguridad
La seguridad de este producto se basa en pruebas y aprobaciones del diseo original y componentes
especficos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. La informacin sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga elctrica y de daos personales durante el desmontaje y la reparacin de la mquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias. PRECAUCIN: este smbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con l, debe conectarlo.

Informaes de Segurana
A segurana deste produto baseia-se em testes e aprovaes do modelo original e de componentes
especficos. O fabricante no responsvel pela segunrana, no caso de uso de peas de substituio no autorizadas. As informaes de segurana relativas a este produto destinam-se a profissionais destes servios e no devem ser utilizadas por outras pessoas. Risco de choques elctricos e ferimentos graves durante a desmontagem e manuteno deste produto. Os profissionais destes servios devem estar avisados deste facto e tomar os cuidados necessrios. CUIDADO: Quando vir este smbolo, existe a possvel presena de uma potencial tenso perigosa na zona do produto em que est a trabalhar. Antes de comear, desligue o produto da tomada elctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente elctrica para realizar a tarefa necessria.

-xviii Service Manual

Informaci de Seguretat
La seguretat d'aquest producte es basa en l'avaluaci i aprovaci del disseny original i els components
especfics. El fabricant no es fa responsable de les qestions de seguretat si s'utilitzen peces de recanvi no autoritzades. La informaci pel manteniment daquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui. El risc de xoc elctric i de danys personals pot augmentar durant el procs de desmuntatge i de servei daquest producte. El personal professional ha destar-ne assabentat i prendre les mesures convenients. PRECAUCI: aquest smbol indica que el voltatge de la part de l'equip amb la qual esteu treballant s perills. Abans de comenar, desendolleu l'equip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.

-xix

Preface
This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General information contains a general description of the printer and the maintenance approach used to 2. 3. 4. 5. 6. 7.
repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed. Diagnostic information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs). Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems. Repair information provides instructions for making printer adjustments and removing and installing FRUs. Connector locations uses illustrations to identify the connector locations and test points on the printer. Preventive maintenance contains the lubrication specifications and recommendations to prevent problems. Parts catalog contains illustrations and part numbers for individual FRUs. Appendix A contains service tips and information.

Conventions
Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. There are several types of caution statements: CAUTION A caution identifies something that might cause a servicer harm.

CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.

CAUTION This type of caution indicates a hot surface.

CAUTION This type of caution indicates a tipping hazard.

-xx Service Manual

1. General information
The Toshiba e-STUDIO450S and 500S are All-In-One laser MFPs that provide print, copy, scan, and fax functions designed to attach to IBM-compatible personal computers and most computer networks. The operator panel is touch-sensitive and allows the user to adjust the viewing angle. These MFPs are available in the following models: Model name e-STUDIO 450S e-STUDIO 500S Configuration Network, modem Network, modem, hard disk Machine type 7002-005 7002-111

Maintenance approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to determine the MPF problem and repair the failure. After you complete the repair, perform tests as needed to verify the repair. See Start on page 2-1.

General information

1-1

Configured models
The following illustrations show and compare standard 450S and 500S MFPs configured with a duplex unit and a 500-sheet drawer. Other print media handling options are also available. Model 500S MFP Standard Model 500S MFP With duplex and drawer

Scanner Standard output bin Control panel

Tray 1 (integrated tray or standard tray) Multipurpose feeder Duplex unit

Tray 1 (integrated tray or standard tray)

Tray 2 (500 sheets)

Model 450S Standard

Model 450S With duplex and drawer

CAUTION Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet drawer. Certain other configurations also must have a printer stand or printer base.

1-2 Service Manual

Options
The following options are available but not in every country or region. Contact your point of purchase for options available in your country or region.

Memory options of 128MB, 256MB, and 512MB SDRAM Flash memory options of 32MB and 64MB Hard disk20GB+ with adapter (model 500S only) Integrated network options Token-Ring Ethernet External serial adapter IPDS card assembly and SCS/TNe PRESCRIBE card assembly Bar code card assembly Parallel interface card Forms card (single-byte and Simplified Chinese) Media handling operations 250- and 500-sheet paper trays of A4, letter, A5, B5, Executive, folio, statement, and legal size 250- and 400-sheet universally adjustable trays 250- and 500-sheet paper drawers 400-sheet universally adjustable tray 2000-sheet high-capacity feederalways used below any other drawer. Envelope feeder Duplex option500-sheet (For 450S with integrated 500-sheet output tray) Application solutions Bar code card IPDS PRESCRIBE emulation card PrintCryption DBCS font cards Simplified Chinese Traditional Chinese Japanese Korean

General information

1-3

Specifications
General
MFP specifications
e-STUDIO 450S Scanner Scanner type Scanner technology Light sources Color flatbed scanner with ADF Charge coupled device (CCD) Two Cold Cathode Fluorescent Lamp (CCFL) and one CCD module per scanner 600 x 600 dpi maximum (mono) 600 x 300 dpi (color) with final resolution 300 x 300 dpi Scan area (flatbed) Scanner ADF ADF type ADF optical resolution Document capacity Media thickness Media weight ADF scan area Printer Print technology Fax Modem (in models with modem) Built-in Group 3 compatible, full function fax 33,600 bps, Max V.34 half duplex Built-in Group 3 compatible, full function fax 33,600 bps, Max V.34 half duplex Hot roll fuser Hot roll fuser Simplex ADF with C-path 600 x 600 dpi maximum 50 sheets (assuming 20 lb./75 g/m2 ) 0.05 mm (minimum) to 0.15 mm (maximum) 15 lb (56 g/m2) to 32 lb (120 g/m2) 8.5 in. x 14.0 in. (216 mm x 355 mm) Single pass duplex ADF with C-path 600 x 600 dpi maximum 50 sheets (assuming 20 lb./75 g/m2) 0.05 mm (minimum) to 0.15 mm (maximum) 15 lb (56 g/m2) to 32 lb (120 g/m2) 8.5 in. x 14.0 in. (216 mm x 355 mm) 8.5 in. x 14 in. (216 mm x 355.6 mm) maximum Color flatbed scanner with ADF Charge coupled device (CCD) Two CCFL and two CCD modules per scanner 600 x 600 dpi maximum (mono) 600 x 300 dpi (color) with final resolution 300 x 300 dpi 8.5 in. x 14 in. (216 mm x 355.6 mm) maximum e-STUDIO 500S

Max optical resolution

Resolution

1200 x 1200 dpi 2400 Image Quality 1200 Image Quality 600 x 600 dpi

Data streams

PostScript 3 emulation PCL 6 emulation PPDS migration tool PDF v1.5 emulation

1-4 Service Manual

Memory configuration
Models

Memory type
Standard DRAM (MB) Optional memory (MB) (One slot100 pin DDR SDRAM unbuffered DIMMs) Maximum (MB) Optional flash memory (MB) Hard disk

e-STUDIO 450S 128

e-STUDIO 500S 256 128, 256, and 512 available

640 32 and 64 available N/A

768

<20GB

Note: One firmware card and one flash memory card are supported. Either slot supports both card types. Depending upon the options and features used, additional memory may be required to optimize performance.

Recommended operating clearances

Dimension Left Right Front Rear Top* Measurement 12 in. (30.5 cm) 8 in. (20.3 cm) 20 in. (50.8 cm) 8 in. (20.3 cm) 12 in. (30.5 cm)

* Allow clearance above the printer front door clearance and for adding options, such as additional input drawers.

General information

1-5

Dimensions
Description Printer e-STUDIO 450S e-STUDIO 500S (with duplex and 500-sheet option) 28.0 in. (710 mm) 35.0 in. (890 mm) 22.0 in. (560 mm) 22.0 in. (560 mm) 25.4 in. (645 mm) 26.0 in. (660 mm) 80.0 lb (34.9 kg)103 lb (46.7 kg) Height Width Depth Weight

Options Duplex 500-page option 250-Sheet drawer 500-Sheet drawer 2,000-Sheet drawer Envelope option (closed position) Envelope option (support fully extended) MFP Stand with Cabinet Low Profile MFP Stand MFP Stand without Cabinet Stability Enhanced Caster Base 10 Inch Cabinet Option 2.0 in. (51 mm) 3.5 in. (90 mm) 5.2 in. (134 mm) 15.0 in. (381 mm) * * 31.5 in. (800 mm) 22.8 in. (579 mm) 31.5 in. (800 mm) 6.0 in. (152 mm) 10.0 in. (255 mm) 15.7 in. (398 mm) 15.7 in. (398 mm) 15.7 in. (398 mm) 15.7 in. (398 mm) * * 22.4 in. (569 mm) 22.4 in. (569 mm) 22.4 in. (569 mm) 27 in. (685 mm) 15.7 in. (397.6 mm) 24.1 in. (595 mm) 18.0 in. (457 mm) 19.0 in. (520 mm) 18.0 in. (457 mm) 7.72 in. (196 mm) 12.28 in. (312 mm) 24.5 in. (622 mm) 24.5 in. (594 mm) 24.5 in. (622 mm) 27.0 in. (686 mm) 17.54 in. (445.7 mm 11.3 lb (5.1 kg) 6 lb (2.7 kg) 7 lb (3.2 kg) 31 lb (14.1 kg) 4 lb (1.8 kg) 4 lb (1.8 kg) 64 lb (29.0 kg) 45 lb (20.4 kg) 64 lb (28.1 kg) 25 lb (11.3 kg) 17.1 lb. (7.8 kg)

* Envelope option fits within height and width of printer.

1-6 Service Manual

Power requirements
Average nominal power requirements for the base printer configuration (110 volt). Power levels are shown in watts (W). Maximum current is given in Amperes (A). Printing states Off Idleaverage power Power Saver on Power Saver off Continuous copying Continuous printing Printingmaximum current 100 V 120 V 230 V 12.3 A 10.5 A 5.4 A 7.8 A 7.2 A 3.4 A 8.9 A 8.0 A 4.1 A 30 W 105 W 650 W 800 W 20 W 90 W 875 W 675 W 20 W 95 W 875 W 830 W e-STUDIO 450S 0W NA .05 W e-STUDIO 500S .05 W

Electrical specifications
Low voltage model 100 to 127 V ac at 50 to 60 Hz nominal 90 to 137 V ac, extreme High voltage model 220 to 240 V ac at 50 to 60 Hz nominal (not available in all countries or regions) 198 to 259 V ac, extreme
Notes:

Using a power converter or inverter is not recommended. All models are ENERGY STAR qualified. All models ship with Power Save Mode on. The default timeout to power saver is 30 minutes for model 500S and 45 minutes for model 450S .

General information

1-7

Environment
Printer temperature and humidity

Operating Temperature: 16 to 32 C (60 to 90 F) Relative humidity: 8 to 80% Altitude: 10,000 ft. (0 to 3,048 meters) Storage and shipping environment (packaged) Temperature: -40 to 43 C (-40 to 110 F) Relative humidity: 5% to 95% Altitude: equivalent to 10,300 meters (0 to 34,000 feet) Storage environment (unpacked) Temperature: 0 to 40 C (32 to 104 F) Relative humidity: 5% to 80%

Acoustics
All measurements are made in accordance with ISO 7779 and conform with ISO 9296. Declared sound power level (Bels) (LpAm) 7.0 7.2 6.8 4.5

Emission sound pressure level (dBA) Mode Bystander position average (LpAm) Standing Operator Position (LpAm) N/A 62 59 N/A

Printing Copying Scanning Ready

56 57 52 30

Note: Measurements apply to 300 dpi, 600 dpi, and 1200 dpi printing.

1-8 Service Manual

Media specifications
Paper and specialty media guidelines
Print media is paper, card stock, transparencies, labels, and envelopes. This printer provides high quality printing on a variety of print media. You must consider a number of things concerning print media before you print, including:

Supported print media Selecting print media Storing print media Avoiding jams

For more details about the types of paper and specialty media your printer supports, refer to your dealer. We recommend that you try a limited sample of any paper or specialty media you are considering using with the printer before purchasing large quantities.

Supported print media

The following tables provide information on standard and optional sources for both input and output trays and bins.

Print media sizes Print media weights Media weights supported in optional output bins
Note: If you use a print media size not listed, select the next larger size.

Print media sizes

Envelope feeder (option)

indicates support
Multipurpose feeder

2000-sheet drawer (option)

Print media size

Dimensions

A4 A5 JIS B5 Letter Legal

210 x 297 mm (8.27 x 11.7 in.) 148 x 210 mm (5.83 x 8.27 in.) 182 x 257 mm (7.17 x 10.1 in.) 215.9 x 279.4 mm (8.5 x 11 in.) 215.9 x 355.6 mm (8.5 x 14 in.)

1 This size does not appear in the Paper Size menu until Tray Size Sensing is turned off. Refer to the User Guide for more information.

This size setting formats the page for 215.9 x 355.6 mm (8.5 x 14 in.) unless the size is specified by the software application.

General information

1-9

Standard output bin

Duplex unit (option)

250-sheet tray

500-sheet tray

250 UAT

400 UAT

2000-sheet drawer (option)

Legend indicates support Multipurpose feeder

Envelope feeder (option)

Print media size

Dimensions

Executive Folio1 Statement1 Universal2

184.2 x 266.7 mm (7.25 x 10.5 in.) 216 x 330 mm (8.5 x 13 in.) 139.7 x 215.9 mm (5.5 x 8.5 in.) 139.7 x 210 mm to 215.9 x 355.6 mm (5.5 x 8.27 in. to 8.5 x 14 in.) 69.85 x 127 mm to 215.9 x 355.6 mm (2.75 x 5 in. to 8.5 x 14 in.) 148 x 182 mm to 215.9 x 355.6 mm (5.83 x 7.17 in. to 8.5 x 14 in.) 76.2 x 127 mm to 215.9 x 355.6 mm (3 x 5 in. to 8.5 x 14 in.) 76.2 x 177.8 mm to 215.9 x 355.6 mm (3 x 7 in. to 9.01 x 14 in.)

7 Envelope 9 Envelope 10 Envelope DL Envelope B5 Envelope C5 Envelope Other Envelope1

98.4 x 190.5 mm (3.875 x 7.5 in.) 98.4 x 225.4 mm (3.875 x 8.87 in.) 104.8 x 241.3 mm (4.12 x 9.5 in.) 110 x 220 mm (4.33 x 8.66 in.) 176 x 250 mm (6.93 x 9.84 in.) 162 x 229 mm (6.38 x 9.01 in.) 98.4 x 162 mm to 176 x 250 mm (3.87 x 6.38 in. to 6.93 x 9.84 in.)

1 This size does not appear in the Paper Size menu until Tray Size Sensing is turned off. Refer to the User Guide for more information. 2 This size setting formats the page for 215.9 x 355.6 mm (8.5 x 14 in.) unless the size is specified by the software application.

1-10 Service Manual

Standard output bin

Duplex unit (option)

250-sheet tray

500-sheet tray

250 UAT

400 UAT

Print media types

Multipurpose feeder 2000-sheet drawer

250-sheet drawer

500-sheet drawer

Paper Card stock Transparencies Vinyl labels* Paper labels* Polyester label* Dual-web and integrated labels*
* Printing

label applications on the MFP requires a special label fuser cleaner. The label fuser cleaner is included with a special label cartridge for label applications.

Print media weights

Print media weight Print media Type Integrated tray and optional 500-sheet drawer 60 to 176 g/m2 grain long (16 to 47 lb bond) 163 g/m 2 (90 lb) 163 g/m 2 (100 lb) 176 g/m 2 (65 lb) 199 g/m 2 (110 lb) 203 g/m 2 (125 lb) 216 g/m 2 (80 lb) 138 to 146 g/m2 (37 to 39 lb bond) Multipurpose feeder and optional 250-sheet drawer 60 to 135 g/m2 grain long (16 to 36 lb bond) 120 g/m 2 (67 lb) 120 g/m 2 (74 lb) 135 g/m 2 (50 lb) 163 g/m 2 (90 lb) 163 g/m 2 (100 lb) 176 g/m 2 (65 lb) 138 to 146 g/m2 (37 to 39 lb bond) n/a Envelope feeder n/a

Paper

Xerographic or business paper Index Bristol Tag Cover

Card stock maximum (grain long)1

Card stock maximum (grain short)1

Index Bristol Tag Cover

Transparencies

Laser printer

General information

1-11

Output bin

Print media

Duplex unit

Print media weight Print media Type Integrated tray and optional 500-sheet drawer Multipurpose feeder and optional 250-sheet drawer Envelope feeder

Labels maximum4

Paper

180 g/m 2 (48 lb bond)

163 g/m 2 (43 lb bond) Note: Not supported in the multipurpose feeder. 163 g/m 2 (43 lb bond) Note: Not supported in the multipurpose feeder. 220 g/m 2 (59 lb bond) Note: Not supported in the multipurpose feeder. 260 g/m 2 (78 lb liner) Note: Not supported in the multipurpose feeder. 140 to 175 g/m2

n/a

Dual-web paper

180 g/m 2 (48 lb bond)

Polyester

220 g/m 2 (59 lb bond)

Vinyl5

300 g/m 2 (92 lb liner)

Integrated forms

Pressuresensitive area (must enter the MFP first) Paper base (grain long)

140 to 175 g/m2

75 to 135 g/m2 (20 to 36 lb bond) Not recommended

75 to 135 g/m2 (20 to 36 lb bond) 60 to 105 g/m2 (16 to 28 lb bond)2, 3 60 to 105 g/m2 (16 to 28 lb bond)3

Envelopes 100% cotton content maximum weight24 lb

Sulfite, woodfree, or up to 100% cotton bonds

Note: 28 lb envelopes are limited to 25% cotton content.

1

Grain short is preferred for papers over 135 g/m 2. envelopes fed from the multipurpose feeder only. 28 lb bond envelopes are limited to 25% cotton content. Printing label applications on the MFP requires a special label fuser cleaner.

2 Includes 3 4

1-12 Service Manual

Selecting print media

Selecting the appropriate print media for the MFP helps you avoid printing problems. The following sections contain guidelines for choosing the correct print media for the MFP.

Paper Transparencies Envelopes Labels Card stock

Paper
For the best print quality, use 75 g/m2 (20 lb) xerographic, grain long paper. Try a sample of any paper you are considering using with the MFP before buying large quantities. When loading paper, note the recommended print side on the paper package, and load paper accordingly.

Paper characteristics
The following paper characteristics affect print quality and reliability. We recommend that you follow these guidelines when evaluating new paper stock. The laser printing process heats paper to high temperatures of 230C (446F). For Magnetic Ink Character Recognition (MICR) applications and for non-MICR applications, use only paper able to withstand these temperatures without discoloring, bleeding, or releasing hazardous emissions. Check with the manufacturer or vendor to determine whether the paper you have chosen is acceptable for laser printers. Weight The MFP can automatically feed paper weights from 60 to 176 g/m2 (16 to 47 lb bond) grain long in the integrated and optional 500-sheet trays and paper weights from 60 to 135 g/m2 (16 to 36 lb bond) grain long in the multipurpose feeder and optional 250-sheet trays. Paper lighter than 60 g/m2 (16 lb) might not be stiff enough to feed properly, causing jams. For best performance, use 75 g/m 2 (20 lb bond) grain long paper. When using paper narrower than 182 x 257 mm (7.2 x 10.1 in.), make sure the weight is greater than or equal to 90 g/m2 (24 lb bond). Unacceptable paper The following papers are not recommended for use with the MFP:

Some 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 MFP Preprinted papers that can be affected by the temperature in the MFP fuser Preprinted papers that require a registration (the precise print location on the page) greater than 0.09 in.,
such as optical character recognition (OCR) forms

In some cases, you can adjust registration with your software application to successfully print on these
forms. Coated papers (erasable bond), synthetic papers, thermal papers Rough-edged, rough or heavily textured surface papers or curled papers Recycled papers containing more than 25% post-consumer waste that do not meet DIN 19 309 Recycled paper having a weight less than 60 g/m2 (16 lb) Multiple-part forms or documents

General information

1-13

Transparencies
The MFP can print directly on transparencies designed for use in laser printers. Print quality and durability depend on the transparency used. Always print samples on the transparencies you are considering before buying large quantities. The Paper Type setting should be set to Transparency to help prevent jams. In Macintosh, be sure to set the Paper Type to Transparency in the Print dialog on the Imaging choice in the Copies & Pages pop-up menu. Use transparencies designed specifically for laser printers. Check with the manufacturer or vendor to determine whether your transparencies are compatible with laser printers that heat transparencies to 230C (446F). Use only transparencies that are able to withstand these temperatures without melting, discoloring, offsetting, or releasing hazardous emissions. Transparencies can be fed automatically from the multipurpose feeder and all standard and optional trays, except the 2000-sheet drawer. Before loading transparencies, fan the stack to prevent sheets from sticking together. Be careful when you handle transparencies. Fingerprints on the surface of the transparency cause poor print quality.

Envelopes
You can load up to 10 envelopes in the multipurpose feeder and 85 envelopes in the envelope feeder. Try a sample of any envelopes you are considering using with the MFP before buying large quantities. When printing on envelopes:

To achieve the best possible print quality, use only high-quality envelopes that are designed for use in laser
printers.

Set the Paper Size/Type in the Paper menu to MP Feeder, Manual Env, or Env Feeder depending on the
source you are using. Set the paper type to Envelope, and select the correct envelope size from the operator panel, the MFP driver, or from MarkVision Professional. For best performance, use envelopes made from 75 g/m2 (20 lb bond) paper. You can use up to 105 g/m2 (28 lb bond) weight for the multipurpose feeder or 105 g/m2 (28 lb bond) weight for the envelope feeder as long as the cotton content is 25% or less. Envelopes with 100% cotton content must not exceed 90 g/m2 (24 lb bond) weight. Use only new, undamaged envelopes. For best performance and to minimize jams, do not use envelopes that: Have excessive curl or twist. Are stuck together or damaged in any way. Contain windows, holes, perforations, cutouts or embossing. Use metal clasps, string ties, or metal folding bars. Have an interlocking design. Have postage stamps attached. Have any exposed adhesive when the flap is in the sealed or closed position. Have nicked edges or bent corners. Have rough, cockle, or laid finishes. Use envelopes that can withstand temperatures of 230C (446F) without sealing, excessive curling, wrinkling, or releasing hazardous emissions. If you have any doubts about the envelopes you are considering using, check with the envelope supplier. Load only one size of envelope at a time in the envelope feeder. A combination of high humidity (over 60%) and the high printing temperatures may seal the envelopes.

1-14 Service Manual

Labels
The MFP can print on many labels designed for use with laser printers. These labels are supplied in letter size, A4 size, and legal size sheets. Label adhesives, face sheet (printable stock), and topcoats must be able to withstand temperatures of 230C (446F) and pressure of 25 pounds per square inch (psi). Try a sample of any labels you are considering using with the MFP before purchasing a large quantity. Note: Labels are one of the most difficult print media for laser MFPs. All MFP models require a special fuser cleaner for label applications to optimize feed reliability. After printing approximately 10,000 pages of labels (or each time you replace the print cartridge), complete the following steps to maintain MFP feeding reliability:

1. Print five sheets of paper. 2. Wait approximately five seconds. 3. Print five more sheets of paper.
When printing on labels:

Set the Paper Size/Type menu item to Labels in the Paper menu. You can set the Paper Size/Type from the
MFP operator panel, the MFP driver, or from MarkVision Professional.

Feed vinyl labels from the standard 250- or 500-sheet trays or the optional 250- or 500-sheet drawers. For
vinyl labels, set the Paper Type to Labels, the Labels Texture to Smooth, and the Label Weight to Heavy, or set the Paper Type to vinyl labels and the texture and weight to normal. Do not load labels with paper or transparencies in the same source; mixing print media can cause feeding problems and print quality problems. Do not use label sheets with a slick backing material. Use full label sheets. Partial sheets may cause labels to peel off during printing, resulting in a jam. Partial sheets also contaminate the MFP and your cartridge with adhesive, and could void the MFP and cartridge warranties. Use labels that can withstand temperatures of 230C (446F) without sealing, excessive curling, wrinkling, or releasing hazardous emissions. Do not print within 1 mm (0.04 in.) of the edge of the label, of the perforations, or between die-cuts of the label. Do not use label sheets that have adhesive to the edge of the sheet. We recommend zone coating of the adhesive at least 1 mm (0.04 in.) away from edges. Adhesive material contaminates the MFP and could void the warranty. If zone coating of the adhesive is not possible, a 1.6 mm (0.1 in.) strip should be removed on the leading and driver edge, and a non-oozing adhesive should be used. Remove a 1.6 mm (0.1 in.) strip from the leading edge to prevent labels from peeling inside the MFP. Portrait orientation is preferred, especially when printing bar codes. Do not use labels that have exposed adhesive.

General information

1-15

Card stock
Card stock is single ply, and has a large array of properties, such as the moisture content, thickness, and texture, that can significantly affect print quality. See Supported print media on page 1-9 for information on the preferred weight and for the grain direction of print media. Try a sample of any card stock you are considering using with the MFP before purchasing a large quantity. After printing approximately 10,000 pages of card stock (or each time you replace the print cartridge), complete the following steps to maintain MFP feeding reliability:

1. Print five sheets of paper. 2. Wait approximately five seconds. 3. Print five more sheets of paper.
When printing on card stock:

Set the Paper Type menu item in the Paper menu to Card Stock from the operator panel, from the MFP
driver, or from MarkVision Professional.

Be aware that preprinting, perforation, and creasing can significantly affect the print quality and cause print
media handling or jamming problems.

Avoid using card stock that may release hazardous emissions when heated. Do not use preprinted card stock manufactured with chemicals that may contaminate the MFP. Preprinting
introduces semi-liquid and volatile components into the MFP.

We recommend the use of grain short card stock.

Storing print media

Use the following guidelines to avoid paper feeding problems and uneven print quality.

Store paper in an environment where the temperature is approximately 21C (70F) and the relative
humidity is 40%. Store cartons of paper on a pallet or shelf rather than directly on the floor. If you store individual packages of paper out of the original carton, make sure they rest on a flat surface so the edges do not buckle or curl. Do not place anything on top of paper packages. Store paper in its original wrapper until you load it into the MFP.

Avoiding jams
Use appropriate print media (paper, transparencies, labels, and card stock) to help ensure trouble-free printing. Note: Try a limited sample of any print media you are considering using with the MFP before purchasing large quantities. By selecting the appropriate print media and loading it properly, you can avoid most jams. The following hints can help you avoid jams:

Use only recommended print media. Do not overload the print media sources. Make sure the stack height does not exceed the maximum height
indicated by the stack line on the labels in the sources.

Do not load wrinkled, creased, damp, or curled print media. Flex, fan, and straighten print media before you load it. If jams do occur with print media, try feeding one
sheet at a time through the multipurpose feeder.

Do not use print media that you have cut or trimmed yourself. Do not mix print media sizes, weights, or types in the same print media source. Make sure the recommended print side is loaded in the source according to your simplex or duplex needs.

1-16 Service Manual

Keep print media stored in an acceptable environment. See Storing print media on page 1-16. Do not remove trays during a print job. Push all trays in firmly after loading them. Make sure the guides in the trays are properly positioned for the size of print media you have loaded. Make sure the guides are not placed too tightly against the stack of print media. If a jam occurs, clear the entire media path.

Tools required
Flat-blade screwdrivers, various sizes Phillips screwdrivers, various sizes 7/32 inch open-end wrench 7.0 mm nut driver 5.5 mm wrench Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax/serial debug cable 1381963 Flash light (optional)

General information

1-17

Acronyms
ADF AIO CCD CRU DIMM DRAM EP EPROM ESD FRU GB HCIT HVPS ITC LASER LCD LED LVPS MDC MFP MPF NVRAM OPT PC PIN PJL POR POST PP PWM RIP SCC SDRAM SIMM UAT USB V ac V dc Automatic Document Feeder All-In-One Charge Coupled Device (CCD) Customer Replaceable Unit Dual Inline Memory Module Dynamic Random Access Memory Electrophotographic process Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte High-Capacity Input Tray High Voltage Power Supply Internal Tray Card Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode Low Voltage Power Supply Motor Driver Control Multifunction Printer Multipurpose Feeder Nonvolatile Random Access Memory Optical Sensor Photoconductor Personal Identification Number Printer Job Language Power-On Reset Power-On Self Test Parts Packet Pulse Width Modulation Raster Imaging Processor Scanner Control Card Synchronous Dynamic Random Access Memory Single Inline Memory Module Universally Adjustable Tray Universal Serial Bus Volts alternating current Volts direct current

1-18 Service Manual

2. Diagnostic information Start

CAUTION Remove the power cord from the printer or from hazardous you connect or disconnect any When you see this symbol, there is a dangerwall outlet beforevoltage in the area of the product cable you are working. or assembly for personal safety and to prevent damage to product whereor electronic boardUnplug the product before you begin, or use caution if thethe printer. must receive power in order to perform the task. CAUTION Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down. Use the service error code, user status message, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer. They will lead you to solutions or service checks, including use of various tests.

Symptom tables
If your machine completes the does not display an error message, and you have a problem, go to Symptom tables on page 2-10. Locate your symptom, and take the appropriate action. The following tables are available:

Service errors (8xx.xx and 9xx.xxs)

If a service error code appears while you are working on the machine, go to Service error codes on page 2-13, and take the indicated action for that error. Service error codes are indicated by a three-digit error code followed by a period and additional numbers in the format XXX.YY. In most cases, five digits are shown.

User status and attendance messages User status messages provide the user with information on the current status of the printer. Ready displays
on the first line of the display unless invoked, and then Power Saver displays. If a user status message is displayed, go to User status displays. on page 2-38. User attendance messages are indicated by a two or three-digit error code that provides the user with information that explains a problem with a print cartridge, paper jam, option, port, and so on. If a user error message displays, go to User attendance messages on page 2-42 and User attendance messagespaper jams and paper handling errors (2xx.xx) on page 2-57.

Additional information
Understanding the MFP operator panel on page 2-2 Menus on page 2-9 Diagnostics Menu on page 3-2 Configuration menu (CONFIG MENU) on page 3-24 Theory on page 3-36 Paper feed jams on page 3-38 Parts catalog on page 7-1

Diagnostic information

2-1

Understanding the MFP operator panel

MFP and scanner settings can be changed several ways: through the MFP operator panel, the software application in use, the print driver, MarkVision Professional, or the Web pages. Settings changed from the application or print driver apply only to the job being sent to the MFP. Changes made to print, fax, copy, and e-mail settings from an application override changes made from the operator panel. If a setting cannot be changed from the application, use the MFP operator panel, MarkVision Professional, or the Web pages. Changing a setting from the MFP operator panel, MarkVision Professional, or the Web pages makes that setting the user default.

MFP operator panels

Model 450S

Models 500S

2-2 Service Manual

Callout 1 2

Operator panel item LCD Indicator light

Function A liquid crystal display (LCD) which shows home screen buttons, menus, menu items, and values. Allows for making selections within Copy, Fax, and so on. Gives information about the status of the MFP using the colors red and green. Status Off Blinking green Solid green Solid red Indicates MFP power is off. MFP is warming up, processing data, or printing a job. MFP is on, but idle. Operator intervention is required.

09 Note: Referred to as the numeric keypad. # (Pound or number character)

Press these buttons to enter numbers when the LCD screen has a field that accepts the entry of numbers. Also, use these buttons to dial phone numbers for faxes. Note: If a number is pressed while on the home screen without pressing the # button first, the Copy menu opens and changes the Copy Quantity. Press this button: For a shortcut identifier. Within phone numbers. For a Fax number with a #, enter it twice ##. From the home screen, the Fax Destination List menu item, E-mail Destination List menu item, or Profile List menu item to access shortcuts. Press to cause a two- or three-second dial pause in a fax number. The button only functions within the Fax menu or with fax functions. Press from the home screen to redial a fax number. When outside of the Fax menu, fax function, or home screen, pressing Dial Pause causes an error beep. When sending a fax, in the Fax To: field, a Dial Pause press is represented by a comma (,). When in the function menus, such as Copy, Fax, E-mail, and FTP, it returns all settings to their default values, and then returns the MFP to the home screen. When in any other menu while the MFP is Ready, it cancels all changes that have not been submitted and returns the MFP to the home screen. Press to initiate the current job indicated on the operator panel. From the home screen, press it to start a copy job with the default settings. If pressed while a job runs through the scanner, the button has no effect. Press to cause the printing or scanning to stop. During a scan job, the scanner finishes scanning the current page and then stops, which means paper may remain in the automatic document feeder (ADF). During a print job, the print media path is cleared before the printing stops. Stopping appears on the operator panel during this process. Within the Copy menu, which is accessed by touching the Copy button, press Backspace to delete the right-most digit of the value in the Copy Count. The default value of 1 appears if the entire number is deleted by pressing Backspace numerous times. Within the Fax Destination List, press Backspace to delete the right-most digit of a number entered manually. It also deletes an entire shortcut entry. Once an entire line is deleted, another press of Backspace causes the cursor to move up one line. Within the E-mail Destination List, press Backspace to delete the character to the left of the cursor. If the entry is in a shortcut, the entire entry is deleted. * is used as part of a fax number or as an alphanumeric character.

Dial Pause

Clear All

Start

Stop

Backspace

10

Asterisk (*)

Diagnostic information

2-3

Callout 11

Operator panel item USB Direct interface

Function The host Universal Serial Bus (USB) direct interface on the operator panel is used to plug in a USB flash memory device and print any Portable Document Format (PDF) [.pdf file], Joint Photographic Experts Group (JPEG) [.jpeg or .jpg file], Tagged Image File Format (TIFF) [.tiff or .tif file], Graphics Interchange Format (GIF) [.gif file], Basic Multilingual Plane (BMP) [.bmp file], Portable Network Graphics (PNG) [.png file], PiCture eXchange (PCX) [.pcx file], and PC Paintbrush File Format [.dcx file] files. The USB direct interface can also be used to scan a document to a USB flash memory device using the PDF, TIFF, or JPEG formats. Returns the LCD to the home screen. Accesses the context-sensitive Help feature. Accesses the menus. These menus are only available when the MFP is in the Ready state. Identifies the location of the contrast wheel. Look on the left side of the MFP near this icon to locate the contrast wheel which adjusts the contrast on the LCD.

12 13 14 15

Home (only on model 450S) Help Tips (only on model 450S) Menu (only on model 450S) Contrast icon (only on model 450S)

Home screen and Home screen buttons

After the MFP is turned on and a short warm-up period occurs, the LCD shows the following basic screen which is referred to as the Home screen. Use the Home screen buttons to initiate an action such as copy, fax, or scan, to open the menu screen, or to respond to messages.

Buttons and touchscreen icon buttons

Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list)
Models 500S Model 450S Button name Copy Function Touch to access the Copy menus. If the home screen is shown, press a number to access the Copy menus, too.

Copy

2-4 Service Manual

Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list) (continued)
Models 500S . Model 450S Button name E-mail Function Touch to access the E-mail menus. It is possible to scan a document directly to an e-mail address.

@
(Icon)

E-mail

(Button)

Menus (A key is shown on the button.)

Touch to access the menus. These menus are only available when the MFP is in the Ready state. For model 500S, the Menus icon is on a gray bar called the navigation bar. For model X642e, the Menu button is on the left side of the operator panel. See Menu (only on model 500S) on page 2-4. Shows the current MFP status such as Ready or Busy. Shows MFP conditions such as Toner Low. Shows intervention messages to give instructions on what the user should do so the MFP can continue processing, such as Close door or insert print cartridge. Appears on the LCD whenever the MFP status includes a message requiring intervention. Touch it to access the messages screen for more information on the message including how to clear it. Tips is a context-sensitive Help feature. For model 500S, all menus have a Tips icon on the touchscreen panel. For model 450S, there is a Tips button on the operator panel, below the touchscreen panel. See Help Tips (only on model 500S) on page 2-4. Touch to access the File Transfer Protocol (FTP) menus. A document can be scanned directly to an FTP site.

Ready.

Status message bar

Status/ Supplies

Status/Supplies

(Icon)

(Button)

? (Tips)

FTP

FTP

Fax

Touch to access the Fax menus.

Fax

(Icon)

(Button)

Home

For model 500S, touch the Home icon to return to the home screen. The Home icon appears on every screen except the home screen. For model 450S, press the Home button on the operator panel below the touchscreen to return to the home screen. See Home (only on model X642e) on page 2-4. There are held faxes with a scheduled hold time previously set. To access the list of held faxes, touch this button.

Release Held Faxes

Release Held Faxes (or Held Faxes if in Manual Mode)

Diagnostic information

2-5

Callout 11

Operator panel item USB Direct interface

Function The host Universal Serial Bus (USB) direct interface on the operator panel is used to plug in a USB flash memory device and print any Portable Document Format (PDF) [.pdf file], Joint Photographic Experts Group (JPEG) [.jpeg or .jpg file], Tagged Image File Format (TIFF) [.tiff or .tif file], Graphics Interchange Format (GIF) [.gif file], Basic Multilingual Plane (BMP) [.bmp file], Portable Network Graphics (PNG) [.png file], PiCture eXchange (PCX) [.pcx file], and PC Paintbrush File Format [.dcx file] files. The USB direct interface can also be used to scan a document to a USB flash memory device using the PDF, TIFF, or JPEG formats. Returns the LCD to the home screen. Accesses the context-sensitive Help feature. Accesses the menus. These menus are only available when the MFP is in the Ready state. Identifies the location of the contrast wheel. Look on the left side of the MFP near this icon to locate the contrast wheel which adjusts the contrast on the LCD.

12 13 14 15

Home (only on model 450S) Help Tips (only on model 450S) Menu (only on model 450S) Contrast icon (only on model 450S)

Home screen and Home screen buttons

After the MFP is turned on and a short warm-up period occurs, the LCD shows the following basic screen which is referred to as the Home screen. Use the Home screen buttons to initiate an action such as copy, fax, or scan, to open the menu screen, or to respond to messages.

Buttons and touchscreen icon buttons

Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list)
Model 500S Model 450S Button name Copy Function Touch to access the Copy menus. If the home screen is shown, press a number to access the Copy menus, too.

Copy

2-4 Service Manual

Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list) (continued)
Models 500S Model 450S Button name Cancel Jobs Cancel Jobs Cancel Jobs Function To open the Cancel Jobs screen. The Cancel Jobs screen shows any of the following items under three headings on the screen which are Print, Fax, and Network: print job copy job fax profile FTP e-mail send Each heading has its own list of jobs shown in a column under the heading. Each column can only show three jobs per screen. The job appears as a button. If more than three jobs exist in a column, then the down arrow appears at the bottom of the column. Each touch of the down arrow accesses one job in the list. When more than three jobs exist, once the fourth job in the list is reached, then an up arrow appears at the top of the column. Model 500SOn the gray navigation bar, these two choices indicate that two types of scanning are possible. One may choose to scan from the ADF or the flatbed.

Cancel Job

Scan the ADF

Scan the ADF Scan the flatbed

Scan the flatbed For both modelsTo save the value as the new user default setting, touch Submit. A green button indicates a choice. If a different value within a menu item is touched, it needs to be saved to become the current user default setting. For model 450STo save the value as the new user default setting, touch Submit. Back Back For all models, touch Back to return to the previous screen, and all the settings for the scan job made on Sample screen one are lost. For both models, when the Back button is shaped like this, no other navigation is possible from this screen Back except to go back. If any other choice is made on the navigation bar, the screen closes. For both models, when the Back button is shaped like this, both forward and backward navigation is possible Back from this screen, so there are other options available on the screen besides selecting Back. Touch the down arrow to move down to the next item in a list, such as a list of menu items or values. The down arrow does not appear on a screen with a short listing. It only appears if the entire listing cannot be seen on one screen. On the last screen of the listing, the down arrow is gray to indicate that it is not active since the end of the list appears on this screen.

Submit

Submit

Back

Down arrow

Diagnostic information

2-7

Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list) (continued)
Models 500S Model 450S Button Up arrow Function Touch the up arrow to move up to the next item in a list, such as a list of menu items or values. When on the first screen presented with a long list, the up arrow is gray to indicate that it is not active. On the second screen needed to show the rest of the listed item, the up arrow is blue to show that it is active. This is an unselected radio button.

Unselected radio button

Selected radio button

This is a selected radio button. Touch a radio button to select it. The radio button changes color to show it is selected. In Sample screen two, the only paper size selected is Letter.

Continue Continue Continue

Touch Continue after a menu item or value on a screen is selected and more changes need to be made for a job from the original screen. Once Continue is touched, the original screen appears.

Custom
Custom

Allows for creating a custom button based on the users needs.

Cancel Cancel Cancel

Touch Cancel to cancel an action or a selection. Touch to cancel out of a screen and return to the previous screen.

Select

Touch to select a menu. The next screen appears showing menu items. Touch to select a menu item. The next screen appears showing values. Allows specifying that a job is finished. For example, when scanning an original document, one could indicate that the last page is scanned, and then printing the job would begin.

Done Done Done

Home

Touch the Home button to return to the home screen. The Home button appears on every screen except the home screen. See the Home screen and Home screen buttons on page 2-4 for more information.

2-8 Service Manual

Menus
A number of menus are available to make it easy for you to change MFP settings or print reports. To access the menus and settings:

Model 500Ptouch the menu icon in the lower right corner of the home screen Model 450Spress the menu button ( ) to the left of the operator panel.
When a value or setting is selected and saved, it is stored in MFP memory. Once stored, these settings remain active until new ones are stored or the factory defaults are restored. Note: Settings chosen for faxing, scanning, e-mailing, copying, and settings for printing from the application may override the settings selected from the operator panel. The following diagram shows the touch screen menu index and the menus and items available under each menu. For more information about menus and menu items, see the Menus and Messages Guide on the Software and Documentation CD.

Paper Menu Default Source Paper Size/Type Configure MP Envelope Enhance Substitute Size Paper Texture Paper Weight Paper Loading Custom Types Custom Names Custom Bin Name (only 500S) Universal Setup Bin Setup (500S) only

Reports Menu Settings Page Device Statistics Network Setup Page Shortcut List Fax Job Log Fax Call Log E-mail Shortcuts Fax Shortcuts FTP Shortcuts Profiles List NetWare Setup Page Print Fonts Print Directory

Manage Shortcuts Manage Fax Shortcuts Manage E-mail Shortcuts Manage FTP Shortcuts Manage Profile Shortcuts

Network/Ports TCP/IP IPv6 E-mail Server Setup Address Book Setup (only 500S) Wireless Standard Network Network <x> Standard USB USB <x> Standard Parallel (only 500S) Parallel <x> Standard Serial Serial <x> NetWare AppleTalk LexLink

Settings General Settings Copy Settings Fax Settings E-mail Settings FTP Settings Print Settings Security Set Date and Time

Help Print all guides Copy guide E-mail guide Fax guide FTP guide Information guide Print defects guide Supplies guide

Diagnostic information

2-9

Symptom tables
Printer symptoms
Symptom Dead machine Touchscreen panel blank, LED is on Touchscreen all white Touchscreen panel blank, LED off, operator panel buttons do not work LCD touchscreen icon buttons do not work LCD touchscreen (monomodel 450S) contrast does not change with contrast control LCD touchscreen (colormodel 500S unable to change LCD touchscreen backlight LCD (monomodel 450S)Home and Help buttons on operator panel do not operate. LCD (monomodel 450S)Menu button on operator panel does not operate. Operator panelnone of the buttons work. Action Go to Dead machine service check on page 2-125. Go to LCD touchscreen display service checkmodel 500S on page 2-149. Go to LCD touchscreen display service checkmodel 500S on page 2-149 Go to Operator panel right cover assembly service check on page 2-154. Go to LCD touchscreen display service checkmodel 500S on page 2-149. Go to LCD touchscreen contrast control service check model450S on page 2-149. Go to LCD touchscreen backlightmodel 500S on page 2-151 Go to Operator panel Help and Home buttons service checkmodel 450S on page 2-154. Go to Operator panel Menu button service checkmodel X642e on page 2-154. Replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64. Replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64. Go to Operator panel right cover assembly service check on page 2-154. Go to Paper feed service checkprinter on page 2-156. Go to Paper feed service checkprinter on page 2-156. Go to Duplex option service check on page 2-127. Go to Fuser solenoid service check on page 2-140. Go to Print qualityall black page on page 2-160. Go to Print qualityblank page on page 2-161. Go to Print qualitylight print on page 2-164. Go to Print qualitybackground on page 2-162. Go to Print qualityresidual image on page 2-163. Go to Paper feed service checkprinter on page 2-156. Go to Print qualitybanding on page 2-163. Go to Print qualityrandom marks on page 2-161. Go to Print qualitytoner on backside of printed page on page 2-164.

Operator panelone button does not work

Operator panel LED does not come on while MFP operates normally Paper feed problemsprinter or integrated 500-sheet paper tray Paper jams at exit of redrive assembly duplex option not installed. Paper jams at exit of redrive assembly duplex option installed. Fuser solenoid fails to operate. Printerblack page (print quality) Printerblank page (print quality) Printerlight print (print quality) Printerbackground (print quality) Printerresidual image (print quality) Printerskew (print quality) Printerbanding (print quality) Printerrandom marks (print quality) Printertoner on backside of printed page. (print quality)

2-10 Service Manual

Printer symptoms (continued)

Symptom Printervertical black bands on edge of copy (print quality) Unable to clear a 32-Unsupported Print Cartridge user error message. Action Go to Print qualityblack bands on outer edges of the page on page 2-163. Go to Signature button assembly service check on page 2-170.

ScannerADF symptoms
Symptom ADF does not recognize paper length in the paper tray ADF does not recognize one or all paper widths of paper in the paper tray Action Go to ADF paper length sensor service checkmodel 500S" on page 2-122. Go to ADF paper width sensor service checkmodel 500S" on page 2-123.

Scannerflatbed symptoms
Symptom Flatbed scanner does not recognize paper size. A blue screen on the touchscreen. The MFP does not come to a Ready state. A clicking noise coming from the back of the MFP between the scanner and the printing unit. Action Go to Flatbed size sensor service check on page 2-131. Go to 843.xx Error code service check on page 2-116 Go to 843.xx Error code service check on page 2-116

Scannerscan quality
Symptom Vertical streaks or lines on image All black or blank page Wavy linesflatbed or mixed mode up to 300 dpi Line compression Action Go to Vertical streaks or lines on image on page 2-165 Go to All black or blank image on page 2-168 Go to Wavy lines on page 2-169 Go to Line compression on page 2-169

High-capacity feeder (2000-sheet) symptoms

Symptom The printer does not recognize the highcapacity feeder installed. Paper feed problem with the high-capacity feeder. Action Go to High-capacity feeder input tray service check on page 2-141. Go to High-capacity feeder input tray service check on page 2-141.

Diagnostic information

2-11

Paper tray symptoms

Symptom Paper feed problem with 250-Sheet Paper Tray. Paper feed problem with 500-Sheet Paper Tray. Media fails to pass through from the lower attached Paper Tray option to the next higher mounted option. Action Go to Input tray(s) service check on page 2-147. Go to Input tray(s) service check on page 2-147. Go to Input tray(s) service check on page 2-147.

Duplex option symptoms

Symptom Paper feed problem with Duplex. Paper jams at Paper Removal Tray. Paper skews in the Duplex Option. Paper fails to pass from lower option through the Duplex Option. Action Go to Duplex option service check on page 2-127. Go to Duplex option service check on page 2-127. Go to Duplex option service check on page 2-127. Go to Duplex option service check on page 2-127.

Envelope feeder symptoms

Symptom Envelopes do not feed from the envelope feeder. Action Go to Envelope feeder service check on page 2-129.

Envelopes do not feed properly into printer. Go to Envelope feeder service check on page 2-129.

2-12 Service Manual

Messages and error codes

Service error codes
Service error codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition. Service error codes are indicated by a three-digit error code followed by a period and additional numbers in the format XXX.YY. In most cases, five digits are shown. Additional sub error codes display if you press and hold Start ( ) and 2 when an error message is displayed. Not all error conditions have additional sub error information.

Sub error codes for 8xx, 9xx, and 2xx error codes
The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the printer, envelope feeder, and duplex option. To display sub error codes (where available) When a 9xx or 2xx error displays:

1. Press and hold Start ( 2. 3.

) and 2 to view for sub error codes. The first screen of information displays. Write down the information. Continue pressing Start and 2 until each screen of information is obtained. When the last screen displays, the original message displays.

Printed error codes Additional information is available by printing the error log. See Print Log on page 3-22.

Service error codes (8xx.xx)

Error code 842 843 Sub codes .xx .xx Display text Service Scanner Service Scanner Description This error indicates that a scanner communications failure. This error indicates that a problems has been detected with the flatbed carriage mechanical hardware. It may also indicate interference between the flatbed CCD assembly and a metal bracket. This error code indicates a failure of the image processing ASIC. There is no modem installed on a modem version of the MFP. Action Go to 842.xx Error code service check on page 2-115. Go to 843.xx Error code service check on page 2-116.

845

.00

Service Image Processing Unit Modem/Config ID Mismatch

Replace the scanner control card (SCC). See Scanner control card removal on page 4-48. Check to see if a modem card is installed in the MFP. If no modem is installed, install a modem card. If the modem is installed, go to 848.00 Error code service check on page 2-118. Remove the modem that has been installed as this MFP does not support a modem.

848

.00

848

.01

Modem/Config ID Mismatch

Modem is present on a no modem version of the MFP.

Diagnostic information

2-13

Service error codes (9xx.xx)

Error code 900 900 901 Sub codes .xx .90 .xx Display text RIP Software 947 Modem Init Failed Engine flash error Defective modem hardware. Indicates that the flash which the system board code is programmed into is bad. Replace the system board. These errors indicate an unrecoverable system software error. These errors indicate an unrecoverable system software error. These errors indicate an unrecoverable system software error. These errors indicate an unrecoverable system software error. These errors indicate an unrecoverable system software error. Check autocompensator cable connectors Check autocompensator for binds Check system board Check autocompensator motor Check system board Check autocompensator Check system board Check autocompensator Check autocompensator assembly Check HVPS Check system board Check HVPS/input sensor/toner sensor cable. Description Action Go to 900.xx Error code service check on page 2-118. Replace the modem card. Replace the system board. See System board and inner shield removal model 500S on page 4-131. Replace the system board. See System board and inner shield removal model 500S on page 4-131. Replace the system board. See System board and inner shield removal model 500S on page 4-131. Replace the system board. See System board and inner shield removal model model 500S on page 4-131. Replace the system board. See System board and inner shield removal model 500S on page 4-131. Replace the system board. See System board and inner shield removal model 500S on page 4-131. Go to Paper feed service check printer on page 2-156.

902

.xx

Engine software error

903

.xx

Paperport link driver error

904

.xx

Interface violation by RIP

905

.xx

Interface violation by Paperport device

906

.xx

RIP interface driver error

910

.xx

DC pick motor acceleration stall (autocompensator motor). DC pick motor excessive PWM DC pick motor underspeed error DC pick motor overspeed error DC pick motor no encoder feedback Problem with transfer transfer servo start error.

911

.00

Go to Paper feed service check printer on page 2-156. Go to Paper feed service check printer on page 2-156. Go to Paper feed service check printer on page 2-156. Go to Paper feed service check printer on page 2-156. Go to Transfer roll service check on page 2-172.

912

.00

913

.00

914 917

.00 .00

2-14 Service Manual

Service error codes (9xx.xx) (continued)

Error code 920 Sub codes .01 Display text Hot roll took too long to heat up after transitioning to new enhanced mode (standby control only. Fuser page count between 0 and 99,999. Hot roll fell too far below the desired temperature while in standby. Fuser page between 0 and 99,999. Description Bad thermistor, circuit or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Incorrect hot roll. Fuser is not receiving AC power. Poor supply line voltage. Action Go to 920.xxCold fuser service check on page 2-132.

920

.02

Go to 920.xxCold fuser service check on page 2-132.

920

.03

Hot roll too cool when checking for slope change in standby. Fuser page count between 0 and 99,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.04

Hot roll too cool when heating to desired temperature after slope change (standby control only). Fuser page count between 0 and 99,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.06

Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count between 0 and 99,999. Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count between 0 and 99,999.

Go to 920.xxCold fuser service check on page 2-132.

920.

.07

Bad thermistor, circuit, or cabling. Very noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Abrupt change in temperature that has disrupted control. Incorrect hot roll.

Go to 920.xxCold fuser service check on page 2-132.

Diagnostic information

2-15

Service error codes (9xx.xx) (continued)

Error code 920 Sub codes .11 Display text Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count between 100,000 and 199,999. Description Bad thermistor, circuit, or cabling. Very noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Fuser is not receiving AC power. Poor supply line voltage. Action Go to 920.xxCold fuser service check on page 2-132.

920

.12

Hot roll fell too far below the desired temperature while printing. Fuser page count between 100,000 and 199,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.13

Hot roll too cool while checking for slope change. Fuser page count between 100,000 and 199,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.14

Hot roll too cool when heating to desired temperature after slope change. Fuser page count between 100,000 and 199,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.16

Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count between 100,000 and 199,999. Fuser has been below the desired temperature for too long while the media is in the nip. Fuser page count between 100,000 and 199,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.17

Bad thermistor, circuit, or cabling. Very noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Incorrect hot roll. Abrupt change in temperature that has disrupted control.

Go to 920.xxCold fuser service check on page 2-132.

2-16 Service Manual

Service error codes (9xx.xx) (continued)

Error code 920 Sub codes .21 Display text Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count between 200,000 and 299,999. Description Bad thermistor, circuit, or cabling. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Fuser is not receiving AC power. Poor supply line voltage. Action Go to 920.xxCold fuser service check on page 2-132.

920

.22

Hot roll fell too far below the desired temperature while printing. Fuser page count between 200,000 and 299,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.23

Hot roll too cool while checking for slope change. Fuser page count between 200,000 and 299,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.24

Hot roll too cool when heating to desired temperature after slope change. Fuser page count between 200,000 and 299,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.26

Fuser is not increasing in temperature even though the lamp has been on for an extended tim. Fuser page count between 200,000 and 299,999. Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count between 200,000 and 299,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.27

Bad thermistor, circuit, or cabling. Very noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Incorrect hot roll. Abrupt change in temperature that has disrupted control.

Go to 920.xxCold fuser service check on page 2-132.

Diagnostic information

2-17

Service error codes (9xx.xx) (continued)

Error code 920 Sub codes .31 Display text Under temperature during steady state control. Fuser page count between 300,000 and 399,999. Description Bad thermistor, circuit, or cabling. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Fuser is not receiving AC power. Poor supply line voltage. Action Go to 920.xxCold fuser service check on page 2-132.

920

.32

Hot roll fell too far below desired temperature while printing. Fuser page count between 300,000 and 399,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.33

Hot roll too cool while checking for slope change. Fuser page count between 300,000 and 399,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.34

Hot roll too cool when heating to desired temperature after slope change. Fuser page count between 300,000 and 399,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.36

Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count between 300,000 and 399,999. Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count between 300,000 and 399,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.37

Bad thermistor, circuit, or cabling. Very noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Incorrect hot roll. Abrupt change in temperatures that has disrupted control.

Go to 920.xxCold fuser service check on page 2-132.

2-18 Service Manual

Service error codes (9xx.xx) (continued)

Error code 920 Sub codes .41 Display text Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count between 400,000 and 499,999. Description Bad thermistor, circuit, or cabling. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Fuser is not receiving AC power. Poor supply line voltage. Action Go to 920.xxCold fuser service check on page 2-132.

920

.42

Hot roll fell too far below the desired temperature while printing. Fuser page count between 400,000 and 499,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.43

Hot roll too cool while chickens for slope change. Fuser page count between 400,000 and 499,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.44

Hot roll too cool when heating to desired temperature after slop change. Fuser page count between 400,000 and 499,999

Go to 920.xxCold fuser service check on page 2-132.

920

.46

Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count between 400,000 and 499,999. Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count between 400,000 and 499,999.

Go to 920.xxCold fuser service check on page 2-132.

920

.47

Bad thermistor, circuit, or cabling. Very noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Incorrect hot roll. Abrupt change in temperatures that has disrupted control.

Go to 920.xxCold fuser service check on page 2-132.

Diagnostic information

2-19

Service error codes (9xx.xx) (continued)

Error code 920 Sub codes .51 Display text Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count more than 500,000. Description Bad thermistor, circuit, or cabling. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Fuser is not receiving AC power. Poor supply line voltage. Action Go to 920.xxCold fuser service check on page 2-132.

920

.52

Hot roll fell too far below desired temperature while printing. Fuser page count more than 500,000.

Go to 920.xxCold fuser service check on page 2-132.

920

.53

Hot roll too cool while checking for slope change. Fuser page count more than 500,000.

Go to 920.xxCold fuser service check on page 2-132.

920

.54

Hot roll too cool when heating to desired temperature after slope change. Fuser page count more than 500,000.

Go to 920.xxCold fuser service check on page 2-132.

920

.56

Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser count more than 500,000. Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count more than 500,000.

Go to 920.xxCold fuser service check on page 2-132.

920

.57

Bad thermistor, circuit, or cabling. Very noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Incorrect hot roll. Abrupt change in temperatures that has disrupted control.

Go to 920.xxCold fuser service check on page 2-132.

2-20 Service Manual

Service error codes (9xx.xx) (continued)

Error code 920 Sub codes .91 Display text Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count not available. Description Bad thermistor, circuit, or cabling. Fuser not receiving AC power. Poor supply line voltage. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Incorrect hot roll. Bad thermistor, circuit, or cabling. Noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Incorrect hot roll. Fuser is not receiving AC power. Poor supply line voltage. Action Go to 920.xxCold fuser service check on page 2-132.

920

.92

Hot roll fell too far below desired temperature while printing. Fuser page count not available.

Go to 920.xxCold fuser service check on page 2-132.

920

.93

Hot roll too cool while checking for slope change. Fuser page count not available.

Go to 920.xxCold fuser service check on page 2-132.

920

.94

Hot roll too cool when heating to desired temperature after slope change. Fuser page count not available.

Go to 920.xxCold fuser service check on page 2-132.

920

.96

Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count not available. Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count not available.

Go to 920.xxCold fuser service check on page 2-132.

920

.97

Bad thermistor, circuit, or cabling. Very noisy thermistor signal. Fuser not receiving AC power. Poor supply line voltage. Excessive load on the fuser. Low voltage or incorrect lamp. Abrupt change in temperatures that has disrupted control.

Go to 920.xxCold fuser service check on page 2-132.

Diagnostic information

2-21

Service error codes (9xx.xx) (continued)

Error code 922 Sub codes .02 Display text Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between 0 and 99,999. Description Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Action Go to 922.xxCold fuser check on page 2-134.

922

.03

Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between 0 and 99,999. Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between 0 and 99,999.

Go to 922.xxCold fuser check on page 2-134.

922

.04

Go to 922.xxCold fuser check on page 2-134.

922

.06

Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 0 and 99,999.

Go to 922.xxCold fuser check on page 2-134.

922

.07

Fuser has taken too long to reach desired temperature after increasing interrupt gap. Fuser page count between 0 and 99,999.

Go to 922.xxCold fuser check on page 2-134.

922

.12

Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between 100,000 and 199,999.

Go to 922.xxCold fuser check on page 2-134.

922

.13

Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between 100,000 and 199,999.

Go to 922.xxCold fuser check on page 2-134.

2-22 Service Manual

Service error codes (9xx.xx) (continued)

Error code 922 Sub codes .14 Display text Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between 100,000 and 199,999. Description Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. The control code has been lost. Action Go to 922.xxCold fuser check on page 2-134.

922

.15

After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count between 100,000 and 199,999. Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 100,000 and 199,999.

Go to 922.xxCold fuser check on page 2-134.

922

.16

Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. The control code has been lost.

Go to 922.xxCold fuser check on page 2-134.

922

.17

Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count between 100,000 and 199,999. Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between 200,000 and 299,999.

Go to 922.xxCold fuser check on page 2-134.

922

.22

Go to 922.xxCold fuser check on page 2-134.

922

.23

Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between 200,000 and 299,999. Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between 200,000 and 299,999.

Go to 922.xxCold fuser check on page 2-134.

922

.24

Go to 922.xxCold fuser check on page 2-134.

922

.25

After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count between 200,000 and 299,999.

Go to 922.xxCold fuser check on page 2-134.

Diagnostic information

2-23

Service error codes (9xx.xx) (continued)

Error code 922 Sub codes .26 Display text Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 200,000 and 299,999. Description Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. The control code has been lost. Action Go to 922.xxCold fuser check on page 2-134.

922

.27

Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count between 200,000 and 299,999. Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between 300,000 and 399,999.

Go to 922.xxCold fuser check on page 2-134.

922

.32

Go to 922.xxCold fuser check on page 2-134.

922

.33

Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between 300,000 and 399,999. Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between 300,000 and 399,999.

Go to 922.xxCold fuser check on page 2-134.

922

.34

Go to 922.xxCold fuser check on page 2-134.

922

.35

After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count between 300,000 and 399,999. Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 300,000 and 399,999.

Go to 922.xxCold fuser check on page 2-134.

922

.36

Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage.

Go to 922.xxCold fuser check on page 2-134.

922

.37

Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count between 300,000 and 399,999.

Go to 922.xxCold fuser check on page 2-134.

2-24 Service Manual

Service error codes (9xx.xx) (continued)

Error code 922 Sub codes .42 Display text Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between 400,000 and 499,999. Description Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. The control code has been lost. Action Go to 922.xxCold fuser check on page 2-134.

922

.43

Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between 400,000 and 499,999. Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between 400,000 and 499,999.

Go to 922.xxCold fuser check on page 2-134.

922

.44

Go to 922.xxCold fuser check on page 2-134.

922

.45

After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count between 400,000 and 499,999. Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 400,000 and 499,999.

Go to 922.xxCold fuser check on page 2-134.

922

.46

Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Excessive load on the fuser. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage.

Go to 922.xxCold fuser check on page 2-134.

922

.47

Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count between 400,000 and 499,999.

Go to 922.xxCold fuser check on page 2-134.

922

.52

Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count stopped at 500,000 to preserve data.

Go to 922.xxCold fuser check on page 2-134.

Diagnostic information

2-25

Service error codes (9xx.xx) (continued)

Error code 922 Sub codes .53 Display text Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count stopped at 500,000 to preserve data. Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count stopped at 500,000 to preserve data. After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count stopped at 500,000 to preserve data. Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count stopped at 500,000 to preserve data. Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count stopped at 500,000 to preserve data. Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count not available. Description Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. The control code has been lost. Action Go to 922.xxCold fuser check on page 2-134.

922

.54

Go to 922.xxCold fuser check on page 2-134.

922

.55

POR the MFP and retry. If the error message remains, go to 922.xxCold fuser check on page 2-134.

922

.56

Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Excessive load on the fuser. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage.

Go to 922.xxCold fuser check on page 2-134.

922

.57

Go to 922.xxCold fuser check on page 2-134.

922

.92

Go to 922.xxCold fuser check on page 2-134.

922

.93

Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count not available.

Go to 922.xxCold fuser check on page 2-134.

2-26 Service Manual

Service error codes (9xx.xx) (continued)

Error code 922 Sub codes .94 Display text Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count not available. Description Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Control code has been lost. Action Go to 922.xxCold fuser check on page 2-134.

922

.95

After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count not available. Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count not available.

POR and retry. If the error message remains, go to 922.xxCold fuser check on page 2-134.

922

.96

Low wattage or incorrect lamp. Bad thermistor, circuit, or cabling. Fuser not receiving sufficient AC power. Poor supply line voltage. Low wattage or incorrect lamp. Excessive load on the fuser. Fuser not receiving sufficient AC power. Poor supply line voltage. Short in the thermistor circuit. Noisy thermistor signal Fuser is actually overheating due to hardware faults. Short in the thermistor circuit. Noisy thermistor signal Fuser is actually overheating due to hardware faults. Short in the thermistor circuit. Noisy thermistor signal Fuser is actually overheating due to hardware faults. Short in the thermistor circuit. Noisy thermistor signal Fuser is actually overheating due to hardware faults. Short in the thermistor circuit. Noisy thermistor signal Fuser is actually overheating due to hardware faults.

Go to 922.xxCold fuser check on page 2-134.

922

.97

Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count not available. Fuser over temperature. Fuser page count between 0 and 99,999.

Go to 922.xxCold fuser check on page 2-134.

923

.01

Go to 923.xxHot fuser service check on page 2-135.

923

.11

Fuser over temperature. Fuser page count between 100,000 and 199,999. Fuser over temperature. Fuser page count between 200,000 and 299,999. Fuser over temperature. Fuser page count between 300,000 and 399,999. Fuser over temperature. Fuser page count between 400,000 and 499,999.

Go to 923.xxHot fuser service check on page 2-135.

923

.21

Go to 923.xxHot fuser service check on page 2-135.

923

.31

Go to 923.xxHot fuser service check on page 2-135.

923

.41

Go to 923.xxHot fuser service check on page 2-135.

Diagnostic information

2-27

Service error codes (9xx.xx) (continued)

Error code 923 Sub codes .51 Display text Fuser over temperature. Fuser page count stopped at 500,000 to preserve data. Fuser over temperature. Fuser page count not available. Description Short in the thermistor circuit. Noisy thermistor signal Fuser is actually overheating due to hardware faults. Short in the thermistor circuit. Noisy thermistor signal Fuser is actually overheating due to hardware faults. Noisy thermistor signal. Intermittent connection. Thermistor cable not connected or thermistor actually open. Noisy thermistor signal. Intermittent connection. Thermistor cable not connected or thermistor actually open. Noisy thermistor signal. Intermittent connection. Thermistor cable not connected or thermistor actually open. Noisy thermistor signal. Intermittent connection. Thermistor cable not connected or thermistor actually open. Noisy thermistor signal. Intermittent connection. Thermistor cable not connected or thermistor actually open. Noisy thermistor signal. Intermittent connection. Thermistor cable not connected or thermistor actually open. Noisy thermistor signal. Intermittent connection. Thermistor cable not connected or thermistor actually open. 115 V lamp in 220 V printer. Lamp has excessive wattage. Action Go to 923.xxHot fuser service check on page 2-135.

923

.91

Go to 923.xxHot fuser service check on page 2-135.

924

.01

Open thermistor check failure. Fuser page count between 0 and 99,999. Open thermistor check failure. Fuser page count between 100,000 and 199,999. Open thermistor check failure. Fuser page count between 200,000 and 299,999. Open thermistor check failure. Fuser page count between 300,000 and 399,999. Open thermistor check failure. Fuser page count between 400,000 and 499,999. Open thermistor check failure. Fuser page count over 500,000.

Go to 924.xxHot fuser service check on page 2-136.

924

.11

Go to 924.xxHot fuser service check on page 2-136.

924

.21

Go to 924.xxHot fuser service check on page 2-136.

924

.31

Go to 924.xxHot fuser service check on page 2-136.

924

.41

Go to 924.xxHot fuser service check on page 2-136.

924

.51

Go to 924.xxHot fuser service check on page 2-136.

924

.91

Open thermistor check failure. Fuser page count not available.

Go to 924.xxHot fuser service check on page 2-136.

925

.01

Lamp detection performed and found error. Fuser page count between 0 and 99,999. Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected. Fuser page count between 0 and 99,999.

Go to 925.xxHot fuser service check on page 2-137.

925

.02

Attempting to POR machine after receiving a 925.01.

Go to 925.xxHot fuser service check on page 2-137.

2-28 Service Manual

Service error codes (9xx.xx) (continued)

Error code 925 Sub codes .11 Display text Lamp detection performed and found error. Fuser page count between 100,000 and 199,999. Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected. Fuser page count between 100,000 and 199,999. Lamp detection performed and found error. Fuser page count between 200,000 and 299,999. Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected. Fuser page count between 200,000 and 299,999. Lamp detection performed and found error. Fuser page count between 300,000 and 399,999. Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected. Fuser page count between 300,000 and 399,999. Lamp detection performed and found error. Fuser page count between 400,000 and 499,999. Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected. Fuser page count between 400,000 and 499,999. Lamp detection performed and found error. Fuser page count stopped at 500,000 to preserve data. Description 115 V lamp in 220 V printer. Lamp has excessive wattage. Action Go to 925.xxHot fuser service check on page 2-137.

925

.12

Attempting to POR machine after receiving a 925.01.

Go to 925.xxHot fuser service check on page 2-137.

925

.21

115 V lamp in 220 V printer. Lamp has excessive wattage.

Go to 925.xxHot fuser service check on page 2-137.

925

.22

Attempting to POR machine after receiving a 925.01.

Go to 925.xxHot fuser service check on page 2-137.

925

.31

115 V lamp in 220 V printer. Lamp has excessive wattage.

Go to 925.xxHot fuser service check on page 2-137.

925

.32

Attempting to POR machine after receiving a 925.01.

Go to 925.xxHot fuser service check on page 2-137.

925

.41

115 V lamp in 220 V printer. Lamp has excessive wattage.

Go to 925.xxHot fuser service check on page 2-137.

925

.42

Attempting to POR machine after receiving a 925.01.

Go to 925.xxHot fuser service check on page 2-137.

925

.51

115 V lamp in 220 V printer. Lamp has excessive wattage.

Go to 925.xxHot fuser service check on page 2-137.

Diagnostic information

2-29

Service error codes (9xx.xx) (continued)

Error code 925 Sub codes .52 Display text Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected. Fuser page count stopped at 500,000 to preserve data. Lamp detection performed and found error. Writes to the fuser information chip have been disabled due to a previous write failure. Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected. Writes to the fuser information chip have been disabled due to a previous write failure. Service fan error. Description Attempting to POR machine after receiving a 925.01. Action Go to 925.xxHot fuser service check on page 2-137.

925

.91

115 V lamp in 220 V printer. Lamp has excessive wattage.

Go to 925.xxHot fuser service check on page 2-137.

925

.92

Attempting to POR machine after receiving a 925.01.

Go to 925.xxHot fuser service check on page 2-137.

927

.00

Loose connector. External blockage of the fan, preventing it from turning. Bad fan. External blockage of fan Fan may not turn due to internal fan problem. Loose connector. External blockage of the fan, preventing it from turning. Bad fan. Loose connector. External blockage of the fan, preventing it from turning. Bad fan. Corrupted feedback signal. Fan input voltage may be too low. Corrupted feedback signal. Fan input voltage may be too low. Corrupted or non-existent feedback signal.

Go to Main fan service check on page 2-119.

927

.01

Main fan stalled.

Go to Main fan service check on page 2-119.

927

.02

Cartridge fan stalled.

Go to Cartridge fan service check on page 2-119.

927

.03

Main fan took too long to ramp up.

Go to Main fan service check on page 2-119.

927

.04

Main fan underspeed or stalled during speed adjustment state. Main fan overspeed during speed adjustment state. Main fan capture data is invalid and speed control is at maximum in fan control idle state.

Go to Main fan service check on page 2-119.

927

.05

Go to Main fan service check on page 2-119.

927

.06

Go to Main fan service check on page 2-119.

2-30 Service Manual

Service error codes (9xx.xx) (continued)

Error code 927 Sub codes .07 Display text Main fan capture data is invalid and speed control is at maximum in fan control adjustment state. Toner sensor errora problem has been detected with the toner sensor. An error has been detected. No home windows has been detected. No toner sensor transition. An incorrect printhead has been detected Printhead lost HSYNC. Description Corrupted feedback signal. Action Go to Main fan service check on page 2-119.

929

.00

Check the toner sensor Check cable Check system board Check toner cartridge. Check toner sensor

Go to Toner sensor service check on page 2-171.

929

.66

Go to Toner sensor service check on page 2-171.

929

.67

Check toner sensor Check toner cartridge Check the printhead Check printhead Check cables and connections Check system board Check printhead Check cables and connectors Check system board. Check printhead Check cables and connections Check system board Check printhead Check system board Check cable connections Defective motor Severe gear blinds in gearbox assembly System board Check cable connections Defective motor Severe gear binds in gearbox assembly. System board Defective motor Defective system board Defective motor Defective system board

Go to Toner sensor service check on page 2-171. Go to Printhead service check on page 2-165. Go to Printhead service check on page 2-165.

930 932

.00 .00

933

.00

Mirror motor locked, no first HSYNC received.

Go to Printhead service check on page 2-165.

934

.00

Mirror motor lost lock

Go to Printhead service check on page 2-165.

936

.00

Mirror moor not up to speed No hall effect detected at motor start. Motor is type 0.

Go to Printhead service check on page 2-165. Go to Main drive service check on page 2-153.

936

.10

936

.11

No hall effect detected at motor start. Motor is type 1.

Go to Main drive service check on page 2-153.

936

.20

Failed to stop within timeout, motor is type 0. Failed to stop within timeout, motor is type 1.

Go to Main drive service check on page 2-153. Go to Main drive service check on page 2-153.

936

.21

Diagnostic information

2-31

Service error codes (9xx.xx) (continued)

Error code 936 Sub codes .30 Display text No lock detected at motor start for motor ID. Motor is type 0. Description Check for paper jams Gear binds Defective motor Check motor cable and connections Check for paper jams Gear binds Defective motor Check motor cable and connections Check for paper jams Gear binds Defective motor Check motor cable and connections Check for paper jams Gear binds Defective motor. Defective motor cable Cable connections Defective cable Check cable connections Defective motor Paper jams Defective cable Check cable connections Defective motor Paper jams Action Go to Main drive service check on page 2-153.

936

.31

No lock detected at motor start for motor ID. Motor is type 1.

Go to Main drive service check on page 2-153.

936

.60

No lock detected at normal motor start. Motor is type 0.

Go to Main drive service check on page 2-153.

936

.61

No lock detected at normal motor start. Motor is type 1.

Go to Main drive service check on page 2-153.

936

.9

Stall detected during speed control. Motor is type 0.

Go to Main drive service check on page 2-153.

936

.91

Stall detected during speed control. Motor is type 1.

Go to Main drive service check on page 2-153.

937

.4

Overspeed detected during speed control. Motor is type 0. Overspeed detected during speed control. Motor is type 1. Overspeed detected during position control. Motor is type 0. Overspeed detected during position control. Motor is type 1. Loss of lock detected by higher level code. Motor is type 0.

Faulty motor sensor Faulty system board Faulty motor sensor Faulty system board Faulty motor sensor Faulty system board Faulty motor sensor Faulty system board Defective motor cable Defective main drive motor Paper jams

Go to Main drive service check on page 2-153. Go to Main drive service check on page 2-153. Go to Main drive service check on page 2-153. Go to Main drive service check on page 2-153. Go to Main drive service check on page 2-153.

937

.41

937

.5

937

.51

937

.7

2-32 Service Manual

Service error codes (9xx.xx) (continued)

Error code 937 Sub codes .71 Display text Loss of lock detected by higher level code. Motor is type 1. Driver over temperature detection. Motor is type 0. RIPengine communications lost. Description Defective motor cable Defective main drive motor Paper jams Excessive gear loading in gearbox assembly System board Action Go to Main drive service check on page 2-153.

937

.80

Go to Main drive service check on page 2-153. POR the printer several times, if the error code continues to be displayed, replace the system board. See System board and inner shield removal model 500s on page 4-131. Check to make sure the correct LVPS assembly has been installed. If the correct supply is installed, check to make sure the LVPS to system board cable is installed correctly. If correct, replace the LVPS assembly. See Low voltage power supply removal on page 4-109. Replace the system board. See System board and inner shield removal model 500S on page 4-131.

939

.00

940

.00

LVPS zero-crossing test failed.

Incorrect LVPS installed Noisy AC power source LVPS to system board cable loose

947

.00

PQET RAM test incomplete, PQET RAM test did not complete, PQET RAM test failed MARCH0 PQET RAM test failed MARCH1 PQET RAM test busy failure Pel clock check failed

PQET failed to pass RAM tests on the system board

948

.00

System board

Replace the system board. See System board and inner shield removal model 500S on page 4-131. Replace the system board. See System board and inner shield removal model 500S on page 4-131. Go to 950.00 through 950.29 EPROM mismatch failure on page 2-120. or go to 950.30 through 950.60 EPROM mismatch failure on page 2-121.

949

.00

Delay line calibration failure

System board

950

.00

NVRAM mismatch

Diagnostic information

2-33

Service error codes (9xx.xx) (continued)

Error code 951 Sub codes .00 Display text Description Action Replace the system board. See System board and inner shield removal model 500S on page 4-131. Warning: When replacing any one of the following components: Flatbed interconnect card System board assembly Interface card assembly Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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.

2-34 Service Manual

Service error codes (9xx.xx) (continued)

Error code 950 Sub codes .30 .60 Display text Service NVRAM mismatch Description EPROM mismatch failure Action This error code indicates a mismatch between the System Board assembly and the interface card assembly. Warning: In the event of replacement of any one of the following components: Flatbed interconnect card System board assembly Interface card assembly Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed above as a method of troubleshooting components. Once a component has been installed in a machine, it cannot be used in another machine. It must be returned to the manufacturer. Go to950.30 through 950.60 EPROM mismatch failure on page 2-121. 952 953 .00 .00 NV failure:n CRC error has occurred. This is recoverable. Perform POR to clear the error. Replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64.

Diagnostic information

2-35

Service error codes (9xx.xx) (continued)

Error code 954 Sub codes .00 Display text Description Action Replace the interface card. See Interface card assembly removal on page 4-107. Warning: When replacing any one of the following components: Flatbed interconnect card System board assembly Interface card assembly Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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. 955 .00 Code CRC CRC failure or ECC code failure on the system board. Replace the system board. See System board and inner shield removal model 500S on page 4-131. Replace the system board. See System board and inner shield removal model 500S on page 4-131. Replace the system board. See System board and inner shield removal model 500S on page 4-131. Replace the system board. See System board and inner shield removal model 500S on page 4-131.

956

.00

System board

This error indicates a system board processor failure.

957

.00

System board

This error indicates a system board processor failure.

958

.00

Nand failure

Printer has performed more than 100 shift and replace operations as a result of EC bit corrections.

2-36 Service Manual

Service error codes (9xx.xx) (continued)

Error code 980 Sub codes .00 Display text Unreliable communications to Paperport device Interface protocol violation by engine Paperport communication error Invalid command received by device Invalid command parameter received by device General device equipment check Description The engine is experiencing unreliable communications to the specified device. The engine protocol violation detected by the specified device. Communications error detected by the specified device. Invalid command received by the specified device. Invalid command parameter received by the specified device. Indicates an equipment check condition has occurred in the specified device, but the device is unable to identify the exact component failure. The specified device has detected an equipment check in its system card. Service errors 980 thru 984 <device> can be one of the following: system board, duplex, tray x (1, 2, 3, 4, or 5), envelope feeder or output bin. Action Service errors 980 thru 984 <device> can be one of the following: system board, duplex, tray x (1, 2, 3, 4, or 5), envelope feeder or output bin.

981 982 983 984

.00 .xx .00 .00

990

.00

991

.00

Device system card failed basic assurance test

Diagnostic information

2-37

User status displays.

User status displays
Sub code Display text Bin [x] Full Description/action x represents the number of the output bin that is full when the MFP bins are linked. Remove print media from the bins. The message clears once the output level of the linked bins is no longer full. The MFP is busy receiving, processing, or printing data. Press Stop to access the job queue. The Delete button is touched after jobs have been selected. The MFP flushes corrupted data and discards the current print job. The MFP is in Hex Trace mode. Hex Trace isolates the source of a print job problem. When Hex Trace is active, all data sent to the MFP prints in hexadecimal and character representation. Exit Hex Trace to print jobs normally. To exit Hex Trace, unplug the MFP. There are not enough system resources at this time. Try again after the current job is complete.

Code

Busy

Deleting selected job(s) Flushing Buffer Hex Trace

Insufficient resources. Try again when the system is idle. Invalid or incorrect password. Invalid PIN.

An incorrect password is entered. Touch Continue to return to the screen to enter a correct password. An incorrect Personal Identification Number (PIN) is entered. Touch Continue to return to the screen to enter a correct PIN. A job in the job list is touched, but it cannot be canceled. The MFP maintenance counter has exceeded its limit, so the MFP requires maintenance. Replace the maintenance items. If necessary, reset the MFP maintenance counter. A network interface is the active communication link. Wait for the message to clear. Notes: The current interface appears on the Menu Settings Page. Interfaces shown without an x or y means the active host interface is a standard interface. x indicates the active interface is connected to the MFP through PCI connector x. x, y indicates the active interface is connected to the MFP through channel y on PCI connector x, or that x equals 0 on the standard network interface. The Delete button is touched when no jobs are selected.

Job cannot be deleted Maintenance

Network Network [x] Network [x], [y]

No jobs selected

2-38 Service Manual

User status displays (continued)

Sub code Display text Parallel Parallel [x] Description/action A parallel interface is the active communication link. Notes: The current interface appears on the Menu Settings Page. Interfaces shown without an x or y means the active host interface is a standard interface. x indicates the active interface is connected to the MFP through PCI connector x. x, y indicates the active interface is connected to the MFP through channel y on PCI connector x, or that x equals 0 on the standard network interface. A serial interface is the active communication link. Notes: The current interface appears on the Menu Settings Page. Interfaces shown without an x or y means the active host interface is a standard interface. x indicates the active interface is connected to the MFP through PCI connector x. x, y indicates the active interface is connected to the MFP through channel y on PCI connector x, or that x equals 0 on the standard network interface. The MFP is processing data through the specified USB port. This is the Printer Job Language (PJL) Ready message. The MFP is ready to receive and process data. It is reducing its electricity consumption while idle. If the MFP remains inactive for the period of time specified in the Power Saver menu item (60 minutes is the factory default), the Power Saver message replaces the Ready message. Send a job to print. Press any operator panel button. The MFP is printing a job. A sheet of print media moves through the MFP to be printed. x represents the number of the sheet being printed. Even though a duplex (two-sided) sheet has two sides, called pages, it only counts as one sheet. A sheet of print media moves through the MFP to be printed. x represents the number of the sheet being printed. Even though a duplex sheet has two sides, called pages, it only counts as one sheet. So, pages are not counted, only sheets passing through the MFP. The total number of sheets in a set is not known, but the number of sets is known. For example, a user may have requested that three copies print, so there are three sets of sheets, but the number of sheets is unknown. A sheet of print media moves through the MFP to be printed. x represents the number of the sheet being printed. A sheet is considered a front and back page of one piece of print media. A group of sheets is called a set. y represents the total number of sheets in a set. a is the number of the current set printing. b is the total number of sets to be printed. For example, a user may send a 6-page duplex print job and select three copies to print. So, there are three sheets to print for each job. This makes one set. Three sets must print before the user has the complete job.

Code

Serial [x]

USB USB [x] [PJL RDYMSG] Power Saver

Printing Printing page [x]

Printing page [x], copy [a] / [b]

Printing page [x]/ [y], copy [a]/[b]

Diagnostic information

2-39

User status displays (continued)

Sub code Display text Ready Description/action The MFP is ready to receive and process jobs. Print, fax, scan, e-mail, copy, or use FTP. The automatic document feeder (ADF) cover is open. Close the cover. The standard bin is full. x represents the number of the bin that is full. [bin name] specifies a previously defined name for the bin, such as Marys bin, and it is full. Remove the stack of print media from the standard output bin or from the specified bin to clear the message. Not all resources needed for the job are available. Wait for the message to clear. Not all resources needed for the job are available. Some held jobs are deleted to free system memory. Wait for the message to clear.

Code

Scanner automatic document feeder cover open Standard Bin Ful Bin [x] Full [bin name] Full

System busy, preparing resources for job. System busy, preparing resources for job. Deleting held job(s). Toner Low

The toner cartridge is low on toner. The Menu Settings Page shows the level. It takes an unspecified amount of time for the MFP to read the level of toner. Until the level is read, the MFP does not show the message. The message clears automatically when the cover or door over the toner cartridge is opened or if the MFP power is turned off and then on. Replace the toner cartridge. If it is not replaced, the MFP issues the message again when the door or cover is closed. x represents the number of the tray. The tray has no print media installed. 1. Remove the tray. The message clears. 2. Install print media in the tray according to the Users Guide. 3. Insert the tray. x specifies the number of the tray that is low. Load print media into the specified tray to clear the message. x represents the number of the tray missing from the MFP. The message is on the Menu Settings Page also. Insert the tray to clear the message. If the Tray 1 Missing message does not clear when tray 1 is inserted, go to Parallel port service check on page 2-159. If Tray 2 through 5 Missing message does not clear by inserting the tray, go to Input tray(s) service check on page 2-147. The MFP receives a page of data to print but waits for an End of Job command, a Form Feed command, or additional data. Press Stop. Touch Continue to print the contents of the buffer. Cancel the current job. Wait for the message to clear.

Tray [x] Empty

Tray [x] Low

Tray [x] Missing

Waiting

Fax status displays

2-40 Service Manual

User status displays (continued)

Sub code Display text Answering Call complete Connect <x>bps Dialing Fax failed Job stored for delayed transmission. Line busy No answer No dial tone Queued for sending Description/action The MFP is answering a fax call. A fax call is completed. The fax is connected. <x> is the baud rate per second. A fax number is dialed. If the number is too long to fit on the screen only the word Dialing appears. The fax failed to send. The scanning completes for a delayed send fax job.

Code

A fax number is dialed, but the fax line is busy. A fax number is dialed, but no connection is made. The MFP does not have a dial tone. The scanning process of a fax job completed, but it is not sent yet because another fax job is being sent or received. As this one job waits for its turn, this message appears for three seconds. The MFP has received an entire fax job. The MFP receives page [n] of the fax job, where n is the number of the page received. The MFP sends page [n] of the fax job, where n is the number of the page sent. The Real Time Clock is not set. This message appears if no other fax status message appears. It remains until the clock is set. Set the clock. The MFP is waiting to redial the fax number.

Receive complete Receiving page [n] Sending page [n] Set clock

Waiting for redial

Diagnostic information

2-41

User attendance messages

User attendance messages
Code Sub code Primary message Change Cartridge Invalid Refill Change [src] to [Custom String] Description/action Select one of the following actions: Remove the toner cartridge and install a new cartridge. Lets the user override the current print media source for the remainder of the print job. The formatted page prints as is on the print media installed in the tray. This may cause clipping of text or images. Touch Use current [src] to ignore the message and print on the print media loaded in the tray. Touch Continue: which continues the job if the correct size and type are loaded in the tray, and this size and type are specified in the Paper Menu using the operator panel. which is ignored if there is no print media in the tray. Touch Cancel job to cancel the current job if needed. New print media is required to finish a print job. Load the indicated source with the requested size and type of print media. Touch Continue to print with print media currently in the tray. Lets the user override the current print media source for the remainder of the print job. The formatted page prints as is on the print media installed in the tray. This may cause clipping of text or images. Touch Use current [src] to ignore the message and print on the print media loaded in the tray. Touch Continue: which continues the job if the correct size and type are loaded in the tray, and this size and type are specified in the Paper Menu using the operator panel. which is ignored if there is no print media in the tray. Touch Cancel job to cancel the current job if needed. Lets the user override the current print media source for the remainder of the print job. The formatted page prints as is on the print media installed in the tray. This may cause clipping of text or images. Touch Use current [src] to ignore the message and print on the print media loaded in the tray. Touch Continue: which continues the job if the correct size and type are loaded in the tray, and this size and type are specified in the Paper Menu using the operator panel. which is ignored if there is no print media in the tray. Touch Cancel job to cancel the current job if needed.

Change <src> to <Custom Type Name>

Change [src] to [size]

Change [src] to [size] [type]

2-42 Service Manual

User attendance messages (continued)

Code Sub code Primary message Check Duplex Connection Description/action This messages displays for the following conditions: The duplex option may have been removed from the printer, possibly to clear a paper jam or to remove the option. The duplex option may be attached to the printer but a communications problem may prevent the printer from detection. For example, there may be a poor connection or a hardware failure. The following actions may be taken: If the option was temporarily removed or not connected properly, reattach or reconnect it. Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on). Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics. If the device is experiencing a hardware problem, turn the printer off and on. If the message continues to be displayed, go to Duplex option service check on page 2-127. Tray x=Tray 2, Tray 3, Tray 4, or Tray 5 This messages displays for the following conditions: The specified device may have been removed from the printer, possibly to clear a paper jam or to uninstall the option. The option may be attached to the printer but a communications problem may prevent the printer from detecting the option. For example, there may be a poor connection or a hardware failure. The following actions may be taken: If the option was temporarily removed or not connected properly, reattach or reconnect it. Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on). Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics. If the device is experiencing a hardware problem, turn the printer off and on. If the message continues to be displayed, go to Input tray(s) service check on page 2-147. During a scanner calibration, the firmware detects that the scanner backing strip for the backside of scan jobs may be dirty. Touch Cancel Job if a scan job is processing when the attendance message appears. This cancels the job and clears the message. Touch Scan from Automatic Document Feeder if the page jam recovery is active. Scanning resumes from the ADF immediately after the last successfully scanned page. Touch Scan from flatbed if page jam recovery is active. Scanning resumes from the flatbed immediately after the last successfully scanned page. Touch Finish job without further scanning if page jam recovery is active. The job ends at the last successfully scanned page, but the job is not canceled. Successfully scanned pages go to their destination: copy, fax, email, or FTP. Touch Restart job if job recovery is active and the job can be restarted. The message clears. A new scan job containing the same parameters as the previous job starts.

Check Tray x Connection

Clean scanner backing strip

Diagnostic information

2-43

User attendance messages (continued)

Code Sub code Primary message Clean scanner glass Description/action During a scanner calibration, the firmware detects that the scanner ADF or flatbed glass may be dirty. Touch Cancel Job if a scan job is processing when the attendance message appears. This cancels the job and clears the message. Touch Scan from Automatic Document Feeder if the page jam recovery is active. Scanning resumes from the ADF immediately after the last successfully scanned page. Touch Scan from flatbed if page jam recovery is active. Scanning resumes from the flatbed immediately after the last successfully scanned page. Touch Finish job without further scanning if page jam recovery is active. The job ends at the last successfully scanned page, but the job is not canceled. Successfully scanned pages go to their destination: copy, fax, email, or FTP. Touch Restart job if job recovery is active and the job can be restarted. The message clears. A new scan job containing the same parameters as the previous job starts. model 500S only. Occurs when the MFP attempts a hard disk recovery on a corrupted hard disk, and the hard disk cannot be repaired. The hard disk must be reformatted. Touch Reformat disk to reformat the hard disk and clear the message. Warning: All files stored on the hard disk are deleted. Model 500S only. The scan job cancels or stops due to insufficient hard disk space. Note: The scanner finishes scanning currently committed pages in the ADF, but data is lost when the job cancels itself. Touch Continue to clear the message. This message displays when the printer front door is open or the print cartridge is missing. If this message cannot be cleared, go to Cover closed switch/cable service checkprinter on page 2-125. Occurs when the MFP detects a missing tray. x can be 1, 2, 3, 4, or 5. Insert the specified tray to clear the message. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. If the message cannot be cleared, go to Paper size sensing service check on page 2-158 or Input tray(s) service check on page 2-147. Bin x=Bin 1, Bin 2, or Bin 3. This message is displayed when a paper handling option has been hot unplugged. The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed. The following actions may be taken: Install the option. Select one of the following: - Cancel Job - Reset Printer - Reset Active Bin If the message cannot be cleared, go to Input tray(s) service check on page 2-147.

Disk corrupted

Disk Full Scan Job Canceled

Insert Cartridge or Close Door

Insert tray [x]

Install Bin x or Cancel Job

2-44 Service Manual

User attendance messages (continued)

Code Sub code Primary message Install Duplex or Cancel Job Description/action This message is displayed when a duplex option has been hot unplugged. The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed. The following actions may be taken: Install the duplex option. Select one of the following: - Cancel Job - Reset Printer - Reset Active Bin If the message cannot be cleared, go to Duplex option service check on page 2-127. The MFP detects that the optional envelope feeder is missing between the time the job processes, but before the job prints. Sometime during processing, the optional envelope feeder is removed. Install the optional envelope feeder. The message clears. Touch Cancel Job if needed. Touch Reset Active Bin to reset the active bin for a linked set of bins. If the message cannot be cleared, go to Envelope feeder service check on page 2-129. The MFP detects that optional Tray [x], where x is the number of the tray, is missing while the job processes, but before the job prints. Sometime during processing, the optional tray is removed. Install the optional tray specified by x. The message clears. Touch Cancel Job if needed. Touch Reset Active Bin to reset the active bin for a linked set of bins. If the message cannot be cleared, go to Input tray(s) service check on page 2-147. Occurs when the MFP receives a manual feed request that a specific print media be loaded into the multipurpose feeder. The print media is previously defined as a custom string which appears on the operator panel. Touch Continue. If print media is in the multipurpose feeder, the job continues to print. If there is no print media in the multipurpose feeder, all requests for additional pages are automatically overridden, and print media is selected from an automatic source. Touch Automatically select media to override manual requests for Manual Paper and Manual Env for the rest of the print job. All requests for additional pages are automatically overridden, and print media is selected from an automatic source. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin.

Install envelope feeder

Install tray [x]

Load manual feeder with [Custom String]

Diagnostic information

2-45

User attendance messages (continued)

Code Sub code Primary message Load manual feeder with [Custom Type Name] Description/action Occurs when the MFP receives a manual feed request that specific print media be loaded into the multipurpose feeder. The print media is previously defined as a custom type from Custom 1 through Custom 6. The custom type name appears on the operator panel. Touch Continue. If print media is in the multipurpose feeder, the job continues to print. If there is no print media in the multipurpose feeder, all requests for additional pages are automatically overridden, and print media is selected from an automatic source. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. Occurs when the MFP receives a manual feed request for a specific size of print media when none is loaded into the multipurpose feeder. Feed a sheet of print media into the multipurpose feeder to clear the message and continue the job. Touch Continue if print media is in the multipurpose feeder. The job continues. Touch Continue if there is no print media in the multipurpose feeder. All requests for additional pages are automatically overridden, and print media is selected from an automatic source. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. Occurs when the MFP receives a manual feed request for a specific size and type of print media when none is loaded into the multipurpose feeder. Touch Continue if print media is in the multipurpose feeder. The job continues. Touch Continue if there is no print media in the multipurpose feeder. All requests for additional pages are automatically overridden, and print media is selected from an automatic source. Touch Automatically select media to override manual requests for Manual Paper and Manual Env for the rest of the print job. All requests for additional pages are automatically overridden and print media is selected from an automatic source. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. Occurs when a source is loaded with an incorrect print media size and type as specified in the Paper Menu. Touch Continue. Load the specified source that is set for the requested size and type. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. Occurs when a source is loaded with an incorrect print media size and type as specified in the Paper Menu. Touch Continue. Load the specified source that is set for the requested size and type. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin.

Load manual feeder with [size]

Load manual feeder with [type] [size]

Load [src] with [Custom String]

Load [src] with [Custom Type Name]

2-46 Service Manual

User attendance messages (continued)

Code Sub code Primary message Load [src] with [size] Description/action Occurs when a source is loaded with an incorrect print media size as specified in the Paper Menu. Touch Continue. Load the specified source that is set for the requested size. Touch Automatically select media to override manual requests for Manual Paper and Manual Env for the rest of the print job. All requests for additional pages are automatically overridden, and print media is selected from an automatic source. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. Occurs when the MFP requests that a specific media source be loaded with a specific type and size as specified in the Paper Menu, but the current source contains an incorrect media size and type. Touch Continue. Load the specified source that is set for the requested size and type. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. The MFP detects that the optional envelope feeder is missing between the time the job processes, and when it prints. Sometime during processing, the optional envelope feeder is removed. Touch Cancel Job to clear the message and continue without using the optional envelope feeder. Install the optional envelope feeder. Bins xy=Bins 1 to 5, Bins 2 to 6, or Bins 6 to 10 This messages displays for the following conditions: The specified output bins may have been removed from the printer, possibly to clear a paper jam or to remove the option. The option(s) may be attached to the printer but a communications problem may prevent the printer from detecting the option. For example, there may be a poor connection or a hardware failure. The following actions may be taken: If the option was temporarily removed or not connected properly, reattach or reconnect it. Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on). Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics. If the device is experiencing a hardware problem, turn the printer off and on. If the message continues to be displayed, go to Input tray(s) service check on page 2-147.

Load [src] with [type] [size]

Reattach envelope feeder

Reattach Bins xy

Diagnostic information

2-47

User attendance messages (continued)

Code Sub code Primary message Reattach Envelope Feeder Description/action This messages displays for the following conditions: The feeder may have been removed from the printer, possibly to clear a paper jam or to remove the option. The feeder may be attached to the printer but a communications problem may prevent the printer from detecting the option. For example, there may be a poor connection or a hardware failure. The following actions may be taken: If the option was temporarily removed or not connected properly, reattach or reconnect it. Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on). Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics. If the device is experiencing a hardware problem, turn the printer off and on. If the message continues to be displayed, go to Envelope feeder service check on page 2-129. Bin x=Bin 1, Bin 2, or Bin 3 This messages displays for the following conditions: The specified output bin may have been removed from the printer, possibly to clear a paper jam or to remove the option. The option may be attached to the printer but a communications problem may prevent the printer from detecting the option. For example, there may be a poor connection or a hardware failure. The following actions may be taken: If the option was temporarily removed or not connected properly, reattach or reconnect it. Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on). Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics. If the device is experiencing a hardware problem, turn the printer off and on. The standard output bin is full of print media. Remove the stack of print media from the bin to clear the message and resume printing. Touch Continue to make the MFP recheck the output level in the standard output bin.

Reattach Output Bin x

Remove paper from standard output bin

2-48 Service Manual

User attendance messages (continued)

Code Sub code Primary message Replace all originals if restarting job. Description/action One or more messages which interrupted a scan job are now cleared. Replace the original documents in the scanner to restart the scan job. Touch Cancel Job if a scan job is processing when the attendance message appears. This cancels the job and clears the message. Touch Scan from Automatic Document Feeder if the page jam recovery is active. Scanning resumes from the ADF immediately after the last successfully scanned page. Touch Scan from flatbed if page jam recovery is active. Scanning resumes from the flatbed immediately after the last successfully scanned page. Touch Finish job without further scanning if page jam recovery is active. The job ends at the last successfully scanned page, but the job is not canceled. Successfully scanned pages go to their destination: copy, fax, email or FTP. Touch Restart job if job recovery is active and the job can be restarted. The message clears. A new scan job containing the same parameters as the previous job starts. The MFP detects that the fuser wiper needs replacing. 1. Replace the fuser wiper. 2. Touch Continue to clear the message. Touch Ignore to clear the message, but at the next power-on, the message appears again. Model 500S only Held jobs are found on the hard disk after a power-on reset of the MFP. Touch Yes to restore the held jobs to the hard disk and make them available. The jobs data remains on the hard disk; however, the job control information is stored in the MFP memory. Touch Quit to stop restoring held jobs before all jobs are restored. Unrestored jobs remain on the hard disk and are retrievable again only at the next power-on reset. Note: A pop-up screen appears to indicate Restoring held jobs(s) xxx/yyy, where xxx indicates the number of the current job being restored, and yyy is the total number of jobs to be restored. Touch Do not restore to have the held jobs remain on the hard disk until they are deleted. The scan job exceeds the maximum number of pages. Note: The scanner finishes scanning current pages in the ADF, but data is lost when the job cancels itself after reaching the maximum number of pages. Touch Continue to clear the message. Touch Cancel Job to clear the message if the job can be restarted. Touch Restart job if the job can be restarted. The message clears, and a new scan job containing the same parameters as the previous job starts. The scanner automatic document feed cover is open. The message clears when the cover is closed. The scanner jam access cover is open. Close the cover to clear the message. Scanner registration is successful. Touch Continue to clear the message.

Replace wiper

Restore held jobs?

Scan Document Too Long

Scanner ADF Cover Open Scanner Jam Access Cover Open Scanner registration successfully completed

Diagnostic information

2-49

User attendance messages (continued)

Code Sub code Primary message Some held jobs were lost Description/action Model 500S only. Occurs when the MFP tries to restore all jobs on a hard disk regardless of the number of held jobs not restored. The message appears once. Touch Continue to clear the message. Some held jobs are not restored. They stay on the hard disk and are inaccessible. The MFP detects a refilled Cartridge Return Program print cartridge. Install a new print cartridge to clear the message. Smart chip cabling loose on controller card. Reseat smart chip cabling inside printer. Replace cartridge. Error code 31 displays when the top front cover is closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 1020 second interval. If pages are allowed to print, they are not reprinted once a good print cartridge is inserted. Note: This error indicates the printer was able to read the cartridge ID, but the ID did not pass the verification test. To pass the verification test, the ID read from the print cartridge must match the ID from the last good print cartridge or the same ID must be read from the print cartridge twice. The last good print cartridge ID is stored in NVRAM. Unsupported cartridge installed. Replace cartridge. Error 32 displays when the top cover is closed and an unsupported print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval. If pages are allowed to print, then they are not reprinted once a good print cartridge is inserted. If this does not fix the problem, go to Signature button assembly service check on page 2-170. The length of the print media is too short to print the formatted data. Touch Continue to clear the message and continue printing. The MFP does not automatically reprint the page that prompted the message. Make sure the Paper Size setting in the Paper Menu is correct for the size of print media used. If MP Feeder Size is set to Universal, make sure the print media is large enough for the formatted data. Touch Cancel Job to cancel the current job if needed. The MFP lacks the memory needed to enable Resource Save. This message usually indicates too much memory is allocated for one or more of the MFP link buffers. Touch Continue to disable Resource Save and continue printing. Install additional memory. The resolution of the page has been reduced from 600 dpi to 300 dpi to prevent a Memory Full error. This message can only occur if the Resolution Reduction setting is turned on. Note: 1200 dpi pages are not resolution reduced. If a 1200 dpi job runs out of memory, a Memory Full error displays.

30

.xx

Invalid refill, change cartridge

31

.00

Defective cartridge

31

.xx

Defective Print Cartridge

32 32

.00 .xx

Unsupported cartridge Unsupported Print Cartridge

34

.xx

Short paper

35

.xx

Insufficient memory to support Resource Save feature

36

.xx

Resolution Reduced

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7002-xxx

User attendance messages (continued)

Code 37 Sub code .xx Primary message Insufficient memory for Flash Memory Defragment operation Description/action The MFP cannot defragment flash memory because the memory used to store undeleted flash resources is full. Touch Continue to clear the message. To perform the defragment operation, install additional memory, or delete fonts, macros, and other data to free some memory space. Touch Reset Active Bin to change to another linked bin. The MFP cannot collate the job because the memory is full. Touch Continue to print the pages processed before the memory became full. Some memory frees up, so collating begins for the remainder of the print job. For example, if a 50-page print job is sent, and 10 copies are requested, and the MFP runs out of memory at page 30, pages 130 would collate and print 10 copies. The MFP would then print and collate pages 3150 and print 10 copies of these pages. Model 500S only. The MFP depletes its memory while it attempts to restore held jobs. The message appears once. Some held jobs are not restored. They stay on the hard disk and are inaccessible. Held jobs are deleted in order to process the current job. The message appears once per job. Touch Continue to clear the message and continue printing. To avoid this error in the future for other jobs, install more memory. Touch Cancel Job to cancel the current job if needed. The MFP is processing data, but the memory used to store pages is full. To avoid this error in the future: Simplify the print job by reducing the amount of text or graphics on a page and deleting unnecessary downloaded fonts or macros. Install additional memory. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. The page may not print correctly because the print information on the page is too complex. To avoid this error in the future: Reduce the complexity of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros. Set Page Protect to On in the Setup Menu in the Settings menu. Install additional memory. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin.

37

.xx

Insufficient memory to collate job

37

.xx

Insufficient memory, some held jobs were lost

37

.xx

Insufficient memory, some Held Jobs were lost

38

.xx

Memory full

39

.xx

Page is too complex to print

Diagnostic information

2-51

User attendance messages (continued)

Code 42 Sub code .xy Primary message Printer/cartridge mismatch Description/action Cartridge region code does not match MFP region code. x=printer region and y=cartridge region. The following regions may be listed: Code Region
0 1 2 3 4 9 Worldwide USA and Canada Europe, Middle East, and Africa Asia Latin America Undefined region

50

.xx

PPDS font error

The MFP has received a request for a font that is not installed when formatting PPDS print data. Touch Continue to clear the message and continue printing the current job. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. The MFP detects a defective flash memory during power-on or during flash format and write operations. Touch Continue to clear the message and continue printing the current job. At power-on reset, touch Continue to clear the message and the MFP continues with normal operations except for flash operations. Install different flash memory to be able to download any resources to flash. There is not enough space in the flash memory to store the data currently being downloaded. Touch Continue to clear the message and continue the print job. Install flash memory with more storage capacity. Download the data. Touch Cancel Job to cancel the current job if needed. Touch Reset Active Bin to change to another linked bin. The MFP detects unformatted flash memory. Touch Continue to clear the message and continue printing. The MFP continues with normal operations except for flash operations. Reformat the flash to allow flash operations. If the error message reappears, the flash memory may be defective and require replacing. The MFP cannot establish communications with a specified installed network port. x indicates the number of the specified port. Touch Continue to clear the message and continue printing. The job may not print correctly. The MFP disables attempts to communicate through the network interface. No data may be sent or received. Reset the MFP. Program new firmware for the network interface.

51

.xx

Defective flash detected

52

.xx

Not enough free space in flash memory for resources

53

.xx

Unformatted flash detected

54

.xx

Network [x] software error

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User attendance messages (continued)

Code 54 Sub code .xx Primary message Serial option [x] error Description/action The MFP detects a serial error, such as framing, parity, or overrun on the specified optional serial port. x is the number of the optional serial port. Make sure the serial link is set up correctly, and the appropriate cable is in use. Make sure the serial interface parameters (protocol, baud, parity, and data bits) are set correctly on the printer and host computer. Touch Continue to clear the message and continue processing the print job; however the print job may not print correctly. Turn the MFP off and then on to reset it. The MFP firmware detects an installed network port, but cannot establish communication with it. Touch Continue to clear the message and continue printing. The job may not print correctly. The MFP disables attempts to communicate through the network interface. No data may be sent or received. Reset the MFP. Program new firmware for the network interface. The MFP detects an unsupported option in the specified slot. x indicates the number of the specified slot. 1. Turn the MFP off. 2. Unplug the power cord from the wall outlet. 3. Remove the unsupported option. 4. Connect the power cord to a properly grounded outlet. 5. Turn the MFP on. A status request occurs over the parallel port, but the parallel port is disabled. Touch Continue. The MFP discards any data received on the parallel port. Touch Reset Active Bin to reset the active bin for a linked set of bins. The MFP receives data across a serial port, but the port is disabled. Touch Continue. The MFP discards any data received on the serial port. Touch Reset Active Bin to change to another linked bin. The MFP receives data through a USB port, but the USB port is disabled. Touch Continue. The printer discards any data received through the USB port. Make sure the USB Buffer menu item is not set to Disabled. Touch Reset Active Bin to change to another linked bin. The MFP receives data through a specified USB port, but this USB port is disabled. x is the number of the USB port. Touch Continue. The MFP discards any data received through the specified USB port. Make sure the USB Buffer menu item is not set to Disabled. Touch Reset Active Bin to change to another linked bin. Model 500S only The MFP fails to restore held jobs due to configuration changes. The message appears once. Some held jobs are not restored. They stay on the hard disk and are inaccessible.

54

.xx

Standard network software error

55

.xx

Unsupported option in slot [x]

56

.xx

Parallel port [x] disabled

56

.xx

Serial port [x] disabled

56

.xx

Standard USB port disabled

56

.xx

USB port [x] disabled

57

.xx

Configuration change, some held jobs were lost

Diagnostic information

2-53

User attendance messages (continued)

Code 58 Sub code Primary message Too many disks installed Description/action Model 500S only. The MFP detects an excess of hard disks installed. 1. Turn the MFP off. 2. Unplug the power cord from the wall outlet. 3. Remove the excess hard disks. 4. Connect the power cord to a properly grounded outlet. 5. Turn the MFP on. The MFP detects an excess of optional flash memory cards installed. Touch Continue to clear the message and ignore the extra optional flash memory cards. The message occurs again unless the excess optional flash memory cards are removed. 1. Turn the MFP off. 2. Unplug the power cord from the wall outlet. 3. Remove the excess flash memory. 4. Connect the power cord to a properly grounded outlet. 5. Turn the MFP on. The MFP detects that too many optional drawers and their matching trays are installed. 1. Turn the MFP off. 2. Unplug the power cord from the wall outlet. 3. Remove the additional drawers. 4. Connect the power cord to a properly grounded outlet. 5. Turn the MFP on. An unsupported optional duplex unit is attached to the MFP. Remove the optional duplex unit. The MFP ceases normal functions until the optional duplex unit is removed. Touch Continue to clear the message once the optional duplex unit is removed. An unsupported optional envelope feeder is attached to the MFP. Remove the optional envelope feeder. The MFP ceases normal functions until the optional envelope feeder is removed. Touch Continue to clear the message once the optional envelope feeder is removed. An unsupported optional drawer and its matching tray are attached to the MFP. Remove the optional drawer. The MFP ceases normal functions until the optional drawer is removed. Touch Continue to clear the message once the optional drawer is removed. Model 500S only. The MFP detects a defective hard disk. 1. Turn the MFP off. 2. Unplug the power cord from the wall outlet. 3. Remove the defective hard disk. 4. Install a new hard disk. 5. Connect the power cord to a properly grounded outlet. 6. Turn the MFP on.

58

Too many flash options installed

58

.xx

Too many trays attached

59

.xx

Incompatible duplex

59

.xx

Incompatible envelope feeder

59

.xx

Incompatible tray [x]

61

.xx

Remove defective disk

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User attendance messages (continued)

Code 62 Sub code .xx Primary message Disk full Description/action Model 500S only. The MFP detects that there is not enough memory or space on the hard disk to store the data of the print job. Touch Continue to clear the message and continue processing the current print job. Any information not previously stored on the hard disk is deleted. Delete fonts, macros, and other data stored on the hard disk. Install a hard disk with a larger memory capacity. Model 500S only The hard disk is not formatted. Format the hard disk prior to performing operations that require the hard disk. If the message remains, the hard disk may be defective and require replacing. Model 500s. The hard disk format is not supported. Format the hard disk prior to performing operations that require the hard disk. If the message remains, the hard disk may be defective and require replacing. Service is required to maintain printer performance. Replace the maintenance items and if necessary, reset the printer maintenance counter. For more information, go to Scheduled maintenance on page 6-1. This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check. POR the MFP to clear the message. The microcode data is discarded and must be re-transmitted from the host computer. The toner cartridge is running low on toner. Replace the toner cartridge if the toner low alarm sounds. Touch Continue to clear the message if the toner low alarm does not sound. The download emulator contained in the firmware card does not function with the MFP firmware. Note: The MFP automatically clears the message in 30 seconds and then disables the download emulator on the firmware card. For help downloading the correct download emulator version, contact the place where you bought your printer.

63

.xx

Unformatted disk

64

.xx

Unsupported disk format

80

.xx

Scheduled maintenance advised

81

.xx

Engine Code CRC Failure

88

.xx

Toner is low

1565

1565

Emul error, load emulation option

Diagnostic information

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User line 2 link messages

If the printer is locked on a particular link, the link indication displays. If the printer is ready to process any link, no messages display. Link messages are listed in the following table. User message Parallel Serial Serial x Network x LocalTalk x Infrared Infrared x Explanation Standard Parallel Port, if available. Standard Serial Port, if available. Serial Port is attached to PCI connector x, where x=1, 2, or 3. Network card x is attached to PCI connector x, where x=1, 2, or 3. LocalTalk Card x is attached to PCI connector x, where x=1, 2, or 3. Standard Infrared port, if available. Infrared Port x is attached to PCI connector x, x=1, 2, or 3.

Check device connection messages

The messages in the following table display when the printer loses communications with one of the following devices. User status message Check Env Feeder Connection Check Tray x Connection Check Duplex Connection Explanation Check envelope feeder connection. Check tray x, where x=1, 2, 3, 4, or 5. Check duplex option connection.

The messages in the following table can occur in two ways. The specified device could have been removed from the printer, for instance to clear a paper jam. Otherwise, the device can still be attached to the printer, but is experiencing a communications problem, not fully connected, or having a hardware failure. If the device is temporarily removed or not connected properly, then the user is advised to reattach it. When the option is recognized, the printer automatically clears the error and continues. If the option is experiencing a hardware problem, turn the printer off and back on. If the error occurs again, the user is advised to turn the printer off, remove the option, and call for service. User status message Turn Printer OFF to Enable Option Explanation A printer option, Input Tray, or Envelope Feeder has been attached while the printer is powered on. To use the option, the printer must first be powered off and back on again. Data loss results if print jobs are active when the printer is power cycled. If a print job is active, then remove the option and finish the job. The printer automatically clears the message once the option is removed. Once the job is complete, turn off the printer and attach the option again. The duplex front access cover is not installed. The duplex rear door is open.

Insert Duplex Front Cover Close Duplex Rear Door

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User attendance messagespaper jams and paper handling errors (2xx.xx)

When the printer jams, the appropriate jam message will be displayed on the printer operator panel. If you select Show Areas on the operator panel, you can view one or more images to help you clear the jam.

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 200 Sub code .00 Description Paper jam around input sensor. Possible causes Multi-sheet feed that is shingled. Tray size sensing wrong size Paper jam leaving page over sensor Action Fan media and stack flat in tray or multipurpose feeder. Check for anything in the paper path that might cause the paper to jam. If clearing a paper jam does not fix the problem, go to Input sensor service check on page 2-146. Fan media and stack flat in tray or MPF. Check for anything in the paper path that might cause the paper to jam. Check cartridge for obstructions. If clearing a paper jam does not fix the problem, go to Input sensor service check on page 2-146. Fan media and stack flat in tray or MPF. Check for anything in the paper path that might cause the paper to jam. Check cartridge for obstructions. If clearing a paper jam does not fix the problem, go to Input sensor service check on page 2-146. Check MPF and friction pad. Fan media and stack flat in tray or MPF. Use different media. Check config ID. Perform a sensor test to check the sensor for the tray. See Sensor Test (input tray) on page 3-14.

200

.01

Input sensor covered too long.

Multi-sheet feed that is shingled. Tray size sensing wrong size. Paper jam leaving page over sensor.

200

.02

Input sensor covered too long.

Multi-sheet feed that is shingled. Tray size sensing wrong size. Paper jam leaving page over sensor.

200

.04

Input sensor covered too quickly

Paper pre-staged in paper path. Wrong configuration ID causes engine to assume 500-sheet paper path on 250-sheet model. Bouncy input sensor. Bouncy pass thru sensor.

200

.06

Imaged page not expected page.

Diagnostic information

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 200 Sub code .07 Description Option tray never picked a page. Possible causes Fail to feed from option. Possible causes may include media edge locking, worn or contaminated pick tires, stacking tray beyond recommended fill line. Action Fan media and stack flat in tray or MPF. Turn media over. Reduce amount of media loaded to fill line. Replace pick tires. Go to Input sensor service check on page 2-146. Check MPF and friction pad. Fan media and stack flat in tray or MPF. Use different media. Check the main drive motor cable connections. If no problem is found with motor connections, go to Main drive service check on page 2-153. Check printhead to system card connections. Check printhead motor system. Go to Printhead service check on page 2-165. Check printhead to system card connections. Check printhead motor system. Go to Printhead service check on page 2-165.

200

.08

Input sensor covered too quickly

Paper pre-staged in path. Bouncy input sensor.

200

.09

Did not receive proper motor feedback to start laser servo.

Motor connections

200

.10

Printhead motor not locked when page crosses input sensor

Printhead lock signal not working. Printhead control not working.

200

.11

Printhead motor fell out of lock after page arrives at input sensor

Paper pre-staged in path. Lock signal went away.

200 200

.12 .13

Timeout while waiting for laser power adjustment. Input sensor covered during warm-up sequence. Page still covering input sensor. Remove cartridge and make sure input sensor is not covered and is in upright position. Go to Input sensor service check on page 2-146. Check MFP mechanism and friction pad. Fan media and stack flat in tray or MPF. Use different media.

200

.14

Gap too small

Paper pre-staged in path. Bouncy input sensor.

200

.15

Laser power did not settle

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 200 Sub code .16 Description Main drive motor error possibly due to mechanical load. Possible causes Main drive motor not working. High mechanical load due to paper jam or bind. Action Make sure paper path is clear Check motor to system card connections. Replace transport motor. Go to Main drive service check on page 2-153. Check cover switch for proper function. Go to Cover closed switch/ cable service checkprinter on page 2-125. Check fuser entry guide for toner build up. Check fuser for wear or contamination. If problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check motor connections to motor and system board. If no problem is found, go to Main drive service check on page 2-153.

200

.32

Detected cover switch bounce.

Upper cover not fully closed. Cover switch not functioning correctly.

201

.00

Page did not reach exit sensor. Fuser page count between 0 and 99,999.

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.01

Main motor identification failed. Main drive motor identification failed. Fuser page count between 0 and 99,999. Page did not reach exit sensor. Fuser page count between 0 and 99,999.

Main motor not working.

201

.02

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

Check fuser entry guide for toner build up. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. If no problem with wear or contamination is found, go to Fuser exit sensor service check on page 2-138

201

.03

Video never started with page two inches past the input sensor. Fuser page count between 0 and 99,999.

Diagnostic information

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 201 Sub code .04 Description Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between 0 and 99,999. Possible causes Page did not enter or exit fuser nip cleanly. Narrow media sensor not functioning correctly. Actual page is narrow when wide page was expected. Action If label media, ensure front edge meets 1/16 inch requirement. Check the fuser for wear or contamination. If found, replace the fuser assembly. See Fuser assembly removal on page 4-79. If media is narrow, then turn off first sheet detection (In Diagnostics Menu, PRINTER SETUP, Engine Settings 3. Select 16 and touch Submit). The fuser narrow media sensor may not be operating properly. Go to Fuser narrow media sensor service check on page 2-139. Check fuser entry guide for toner build up. Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check motor to system board connections. Replace the main drive motor. Main drive assembly removal on page 4-113. Check fuser entry guide for toner build up. Check fuser for wear or contamination. if a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning correctly. Go to Fuser exit sensor service check on page 2-138.

201

.10

Page did not reach exit sensor. Fuser page count between 100,000 and 199,999.

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.11

Main drive motor identification failed. Fuser page count between 100,000 and 199,999. Page did not reach exit sensor. Fuser page count between 100,000 and 199,999.

Main drive motor not working.

201

.12

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.13

Video never started with page two inches past the input sensor. Fuser page count between 100,000 and 199,999.

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Code 201 Sub code .14 Description Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between 100,000 and 199,999. Possible causes Page did not enter or exit fuser nip cleanly. Narrow media sensor not functioning correctly. Actual page is narrow when wide page was expected. Action If label media, ensure front edge meets 1/8 inch requirement. Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. If media is narrow, then turn off first sheet detection (In Diagnostics Menu, PRINTER SETUP, Engine Settings 3. Select 16 and touch Submit). The fuser narrow media sensor may not be operating properly. Go to Fuser narrow media sensor service check on page 2-139. Check fuser entry guide for toner build up. Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check motor connections to motor and system board. If no problem is found, go to Main drive service check on page 2-153. Check fuser entry guide for toner build up. Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138.

201

.20

Page did not reach exit sensor. Fuser page count between 200,000 and 299,999.

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.21

Main drive motor identification failed. Fuser page count between 200,000 and 299,999. Page did not reach exit sensor. Fuser page count between 200,000 and 299,999.

Main drive motor not working.

201

.22

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.23

Video never started with page two inches past the input sensor. Fuser page count between 200,000 and 299,999.

Diagnostic information

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 201 Sub code .24 Description Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between 200,000 and 299,999 Possible causes Page did not enter or exit fuser nip cleanly. Narrow media sensor not functioning correctly. Actual page is narrow when wide page was expected. Action If label media, ensure front edge meets 1/8 inch requirement. Check fuser for wear or contamination. If problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. If media is narrow, then turn off first sheet detection (In Diagnostics Menu, PRINTER SETUP, Engine Settings 3. Select 16 and touch Submit). The fuser narrow media sensor may not be functioning properly. Go to Fuser narrow media sensor service check on page 2-139. Check the fuser entry guide for toner build up. Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the motor connections to motor and system board. If no problem is found, go to Main drive service check on page 2-153. Check the fuser entry guide for toner build up. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138.

201

.30

Page did not reach exit sensor. Fuser page count between 300,000 and 399,999

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.31

Main drive motor identification failed. Fuser page count between 300,000 and 399,999. Page did not reach exit sensor. Fuser page count between 300,000 and 399,999.

Main drive motor not working.

201

.32

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.33

Video never started with page two inches past the input sensor. Fuser page count betwee 300,000 and 399,999.

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Code 201 Sub code .34 Description Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between 300,000 and 399,999. Possible causes Page did not enter or exit fuser nip cleanly. Narrow media sensor not functioning correctly. Actual page is narrow when wide page was expected. Action If label media, ensure front edge meets 1/8 inch requirement. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. If media is narrow, then turn off first sheet detection (In Diagnostics Menu, PRINTER SETUP, Engine Settings 3. Select 16 and touch Submit). The fuser narrow media sensor may not be functioning properly. Go to Fuser narrow media sensor service check on page 2-139. Check fuser entry guide for toner build up. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the motor connections to motor and system board. If no problem is found, go to Main drive service check on page 2-153. Check the fuser entry guide for toner build up. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138.

201

.40

Page did not reach exit sensor. Fuser page count between 400,000 and 499,999.

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.41

Main drive motor identification failed. Fuser page count between 400,000 and 499,999. Page did not reach exit sensor. Fuser page count between 400,000 and 499,999.

Main drive motor not working.

201

.42

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.43

Video never started with page two inches past the input sensor. Fuser page count between 400,000 and 499,999.

Diagnostic information

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 201 Sub code .44 Description Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between 400,000 and 499,999. Possible causes Page did not enter or exit fuser nip cleanly. Narrow media sensor not functioning correctly. Actual page is narrow when wide page was expected. Action If label media, ensure front edge meets 1/8 inch requirement. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. If media is narrow, then turn off first sheet detection (In Diagnostics Menu, PRINTER SETUP, Engine Settings 3. Select 16 and touch Submit). The fuser narrow media sensor may not be functioning properly. Go to Fuser narrow media sensor service check on page 2-139. Check the fuser entry guide for toner build up. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the connections to the motor and system board. If not problem is found, go to Main drive service check on page 2-153. Check the fuser entry guide for toner build up. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138.

201

.50

Page did not reach exit sensor. Fuser page count more than 500,000.

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.51

Main drive motor identification failed. Fuser page count more than 500,000. Page did not reach exit sensor. Fuser page count more than 500,000.

Main drive motor not working.

201

.52

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor is not functioning correctly.

201

.53

Video never started two inches past the input sensor. Fuser pager count more than 500,000.

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Code 201 Sub code .54 Description Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count stopped at 500,000 to preserve data. Possible causes Page did not enter or exit fuser nip cleanly. Narrow media sensor not functioning correctly. Actual page is narrow when wide page was expected. Action If label media, ensure front edge meets 1/8 inch requirement. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. If media is narrow, then turn off first sheet detection (In Diagnostics Menu, PRINTER SETUP, Engine Settings 3. Select 16 and touch Submit). The fuser narrow media sensor may not be functioning properly. Go to Fuser narrow media sensor service check on page 2-139. Check the fuser entry guide for toner build up. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the connections to the motor and system board. If not problem is found, go to Main drive service check on page 2-153. Check the fuser entry guide for toner build up. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138.

201

.90

Page did not reach exit sensor. Fuser page count is not available.

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.91

Main drive motor identification failed. Fuser page count is not available. Page did not reach exit sensor. Fuser page count is not available.

Main drive motor not working.

201

.92

Page jammed on fuser input guide. Page did not enter or exit fuser nip cleanly. Exit sensor not functioning correctly.

201

.93

Video never started two inches past the input sensor. Fuser page count is not available.

Diagnostic information

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 201 Sub code .94 Description Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count is not available. Possible causes Page did not enter or exit fuser nip cleanly. Narrow media sensor not functioning correctly. Actual page is narrow when wide page was expected. Action If label media, ensure front edge meets 1/8 inch requirement. Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See Fuser assembly removal on page 4-79. If media is narrow, then turn off first sheet detection (In Diagnostics Menu, PRINTER SETUP, Engine Settings 3. Select 16 and touch Submit). The fuser narrow media sensor may not be functioning properly. Go to Fuser narrow media sensor service check on page 2-139. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output option(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138.

202

.00

Paper jam at fuser exit or redrive area. Fuser page count between 0 and 99,999.

Page may be jammed in fuser exit or redrive area.

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Code 202 Sub code .01 Description Page did not cleanly exit fuser or redrive area. Fuser page count between 0 and 99,999. Possible causes Page may be jammed in fuser exit or redrive area. Action Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output option(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output option(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the fuser for any signs of a piece of media stuck in the fuser. If the problem recurs, go to 202.03 Error code service check on page 2-95.

202

.02

Exit sensor covered too long. Fuser page count between 0 and 99,999.

Page may be jammed in fuser exit or redrive area.

202

.03

Page is covering narrow media sensor during warm up. Fuser page count between 0 and 99,999.

If page is not visible from front or rear of machine, partial piece of page may be torn off in fuser covering narrow media sensor. Narrow media sensor or flag may be dislodged/damaged.

Diagnostic information

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .04 Description Exit sensor bounced. Fuser page count between 0 and 99,999. Never sent the divert command to the stacker. Fuser page count between 0 and 99,999. Page is covering exit sensor during warm up. Fuser page count between 0 and 99,999. Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media. If the problem recurs, go to 202.06 Error code service check on page 2-95. Possible causes Exit sensor assembly. Action Go to Fuser exit sensor service check on page 2-138.

202

.05

202

.06

202

.07

Timeout waiting for the page ahead. Fuser page count between 0 and 99,999. Divert media command issued too soon. Fuser page count between 0 and 99,999. Virtual page timed out waiting for last page of job to be safe in the stapler accumulator. Fuser page count between Paper jam around fuser or redrive area. Fuser page count between 100,000 and 199,999. Page may be jammed in fuser exit or redrive area. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138.

202

.08

202

.09

202

.10

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Code 202 Sub code .11 Description Page did not cleanly exit fuser or redrive area. Fuser page count between 100,000 and 199,999. Possible causes Page may be jammed in fuser exit or redrive area. Action Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.

202

.12

Exit sensor covered too long. Fuser page count between 100,000 and 199,999.

Page may be jammed in fuser exit or redrive area.

202

.13

Page is covering narrow media sensor during warm up. Fuser page count between 100,000 and 199,999.

If page is not visible from front or rear of the machine, partial piece may be torn off in the fuser covering the narrow media sensor. The narrow media sensor or flag may be dislodged or damaged.

Diagnostic information

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .14 Description Exit sensor bounced. Fuser page count between 100,000 and 199,999. Never sent the divert command to the stacker. Fuser page count between 100,000 and 199,999. Page is covering exit sensor during warm up. Fuser page count between 100,000 and 199,999. Timeout waiting for the page ahead. Fuser page count between 100,000 and 199,999. Divert media command issued too soon. Fuser page count between 100,000 and 199,999. Virtual page timed out waiting for the last page of the job to be safe in the stapler accumulator. Fuser page count between 100,000 and 199,999. Paper jam around fuser exit or redrive area. Fuser page count between 200,000 and 299,999. Paper may be jammed in fuser exit or redrive area. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media. Possible causes Exit sensor assembly. Action Go to Fuser exit sensor service check on page 2-138.

202

.15

202

.16

202

.17

202

.18

202

.19

202

.20

2-70 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .21 Description Page did not cleanly exit fuser or redrive area. Fuser page count between 200,000 and 299,999. Possible causes Page may be jammed in fuser exit or redrive area. Action Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.

202

.22

Exit sensor covered too long. Fuser page count between 200,000 and 299,999.

Page may be jammed in fuser exit or redrive area.

202

.23

Page is covering narrow media sensor during warm up. Fuser page count between 200,000 and 299,999.

If page is not visible from front or rear of the printer, a partial piece of page may be torn off in the fuser covering the narrow media sensor. The narrow media sensor or flag may be dislodged or damaged.

Diagnostic information

2-71

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .24 Description Exit sensor may have bounced. Fuser page count between 200,000 and 299,999. Never sent the divert command to the stacker. Fuser page count between 200,000 and 299,999. Page is covering the exit sensor during warm up. Fuser page count between 200,000 and 299,999. Timeout waiting for the page ahead. Fuser page counter between 200,000 and 299,999. Divert media command issued too soon. Fuser page count between 200,000 and 299,999. Virtual page timed out waiting for last page of job to be safe in the stapler accumulator. Fuser page count between 200,000 and 299,999. Paper jam around the fuser exit or redrive area. Fuser page count between 300,000 and 399,999. Page may be jammed in fuser exit or redrive area. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Something is keeping the exit sensor covered. A page may not have been cleared from a prior jam. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media. Possible causes Exit sensor assembly Action Go to Fuser exit sensor service check on page 2-138.

202

.25

202

.26

202

.27

202

.28

202

.29

202

.30

2-72 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .31 Description Page did not cleanly exit fuser or redrive area. Fuser page count between 300,000 and 399,999. Possible causes Page may be jammed in fuser exit or redrive area. Action Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.

202

.32

Exit sensor covered too long. Fuser page count between 300,000 and 399,999.

Page may be jammed in fuser exit or redrive area.

202

.33

Page is covering the narrow media sensor during warm up. Fuser page count between 300,000 and 399,999.

If page is not visible from front or rear of the printer, a partial piece of a page may be torn off in the fuser covering the narrow media sensor. The narrow media sensor or flag may be dislodged or damaged.

Diagnostic information

2-73

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .34 Description Exit sensor may have bounced. Fuser page count between 300,000 and 399,999. Never sent the divert command to the stacker. Fuser page count between 300,000 and 399,999. Page is covering the exit sensor during warm up. Fuser page count between 300,000 and 399,999. Timeout waiting for the page ahead. Fuser page count between 300,000 and 399,999. Divert media command issued too soon. Fuser page count between 300,000 and 399,999. Virtual page timed out waiting for last page of job to be safe in the stapler accumulator. Fuser page count between 300,000 and 399,999. Paper jam around the fuser exit or redrive area. Fuser page count between 400,000 and 499,999. Page may be jammed in fuser exit or redrive. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Something is keeping the exit sensor covered. A page may not have been cleared from a prior jam. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media. Possible causes Exit sensor assembly. Action Go to Fuser exit sensor service check on page 2-138.

202

.35

202

.36

202

.37

202

.38

202

.39

202

.40

2-74 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .41 Description Page did not cleanly exit fuser or redrive area. Fuser page count between 400,000 and 499,999. Possible causes Page may be jammed in fuser exit or redrive area. Action Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.

202

.42

Exit sensor covered too long. Fuser page count between 400,000 and 499,999.

Page may be jammed in fuser exit or redrive area.

202

.43

Page is covering narrow media sensor during warm up. Fuser page count between 400,000 and 499,999.

If page is not visible from front or rear of the printer, a partial piece of a page may be torn off in the fuser covering the narrow media sensor. The narrow media sensor or flag may be dislodged or damaged.

Diagnostic information

2-75

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .44 Description Exit sensor may have bounced. Fuser page count between 400,000 and 499,999. Never sent the divert command to the stacker. Fuser page count between 400,000 and 499,999. Page is covering the exit sensor during warm up. Fuser page count between 400,000 and 499,999. Timeout waiting for the page ahead. Fuser page count between 400,000 and 499,999. Divert media command issued too soon. Fuser page count between 400,000 and 499,999. Virtual page timed out waiting for last page of job to be safe in the stapler accumulator. Fuser page count between 400,000 and 499,999. Paper jam around the fuser exit or redrive area. Fuser page count stopped at 500,000 to preserve data Page may be jammed in the fuser exit or redrive area. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media. Possible causes Exit sensor assembly Action Go to Fuser exit sensor service check on page 2-138.

202

.45

202

.46

202

.47

202

.48

202

.49

202

.50

2-76 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .51 Description Page did not cleanly exit fuser or redrive area. Fuser page count stopped at 500,000 to preserve data. Possible causes Page may be jammed in fuser exit or redrive area. Action Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.

202

.52

Exit sensor covered too long. Fuser page count stopped at 500,000 to preserve data.

Page may be jammed in fuser exit or redrive area.

202

.53

Page is covering narrow media sensor during warm up. Fuser page count stopped at 500,000 to preserve data.

If page is not visible from front or rear of the printer, a partial piece of a page may be torn off in the fuser covering the narrow media sensor. The narrow media sensor or flag may be dislodged or damaged.

Diagnostic information

2-77

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .54 Description Exit sensor may have bounced. Fuser page count stopped at 500,000 to preserve data. Never sent the divert command to the stacker. Fuser page count more than 500,000. Page is covering the exit sensor during warm up.Fuser page count stopped at 500,000 to preserve data. Timeout waiting for the page ahead. Fuser page count more than 500,000. Divert media command issued too soon. Fuser page count more than 500,000. Virtual page timed out waiting for last page of job to be safe in the stapler accumulator. Fuser page count more than 500,000. Paper jam around the exit or redrive area. Fuser page count is not available. Page may be jammed in fuser exit or redrive area. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media. Possible causes Exit sensor assembly. Action Go to Fuser exit sensor service check on page 2-138.

202

.55

202

.56

202

.57

202

.58

202

.59

202

.90

2-78 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .91 Description Page did not cleanly exit fuser or redrive area. Fuser page count is not available. Possible causes Page may be jammed in the fuser exit or redrive area. Action Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Make sure the redrive door is complete closed. Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See Fuser assembly removal on page 4-79. Turn media over to reduce +W curl. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check any installed output options(s) that may be installed for correct installation and alignment. The fuser exit sensor may not be functioning properly. Go to Fuser exit sensor service check on page 2-138. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.

202

.92

Exit sensor covered too long. Fuser page count is not available.

Page may be jammed in the fuser exit or redrive area.

202

.93

Page is covering narrow media sensor during warm up. Fuser count is not available.

If page is not visible from front or rear of the printer, a partial piece of a page may be torn off in the fuser covering the narrow media sensor. The narrow media sensor or flag may be dislodged or damaged.

Diagnostic information

2-79

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 202 Sub code .94 Description Exit sensor may have bounced. Fuser page count is not available. Never sent the divert command to the stacker. Fuser page count is not available. Page is covering the exit sensor during warm up. Fuser page count is not available. Timeout waiting for the page ahead. Fuser page count is not available. Divert media command issued too soon. Fuser page count is not available. Virtual page timed out waiting for last page of job to be safe in the stapler accumulator. Fuser page count is not available. Paper did not arrive at the duplex input sensor but did leave the printer exit sensor. Duplex rear door not fully latched. Printer diverter not functioning correctly. Duplex feed system not working correctly. Printer and duplex not aligned. Make sure the duplex assembly rear door is properly latched. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check duplex unit for correct installation and alignment to the printer. If available, try another duplex unit. If none is available, go to 231.xx Jam displays on page 2-128. Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam. Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media. Possible causes Exit sensor assembly. Action Go to Fuser exit sensor service check on page 2-138.

202

.95

202

.96

202

.97

202

.98

202

.99

231

.00

2-80 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 232 Sub code .00 Description Paper did not clear the duplex input sensor but did leave the printer exit sensor. Possible causes Duplex rear door not fully latched. Printer diverter not functioning correctly. Duplex feed system not working correctly. Printer and duplex not aligned. Action Make sure the duplex assembly rear door is properly latched. Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary. Check duplex unit for correct installation and alignment to the printer. If available, try another duplex option. If none is available, go to 232.xx Jam displays on page 2-128. Make sure the duplex assembly rear door is properly latched. If available, try another duplex option. If none is available, go to 233.xx Jam displays on page 2-128. Check the media coming from the printer to the duplex option is not damaged or skewed. If the media is not damaged or skewed, try another duplex option, if available. If not available, replace the duplex option. Remove the two sheets from the duplex option and see if the duplex fails again. Remove the sheets if it fails again. Run the duplex Feed 1 and Feed 2 Tests to see if they pass. See Duplex Feed 1 and Duplex Feed 2 on page 3-13. If the tests fail after several attempts, replace the duplex option. If the tests pass, retry to feed from the printer through the duplex option. If the problem is still present, replace the duplex option.

233

.00

Paper failed to make duplex doublefeed sensor during turnaround.

Duplex rear door not fully latched. Duplex feed system not working correctly.

234

.00

Paper did not arrive at duplex exit sensor.

Duplex rear door not fully latched. Duplex feed system not working correctly. Severely skewed media coming from the printer.

235

.00

Paper reached the duplex exit sensor but another sheet is still detected over the doublefeed sensor.

Double feed separated in duplex.

Diagnostic information

2-81

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 236 Sub code 00 Description Paper did not leave the duplex exit sensor. Possible causes Duplex jam access tray is not fully latched. Printer PTO not driving duplex feed rolls. Duplex feed system not working correctly. Action Make sure the duplex jam access tray is installed correctly Make sure the power takeoff shaft and spring are correctly installed and operating properly. Try the duplex option again. If it fails try another duplex option, if available. If another one is not available, replace the duplex option. Make sure the duplex jam access tray is installed correctly Make sure the power takeoff shaft and spring are correctly installed and operating properly. Try the duplex option again. If it fails try another duplex option, if available. If another one is not available, replace the duplex option. Make sure the duplex jam access tray is installed correctly Make sure the power takeoff shaft and spring are correctly installed and operating properly. Try the duplex option again. If it fails try another duplex option, if available. If another one is not available, replace the duplex option. Remove any sheets from the duplex option. Try the duplex option again. If it fails, try another duplex option, if available. If one is not available, replace the duplex option. Remove any sheets from the duplex option. Try the duplex option again. If it fails, try another duplex option, if available. If one is not available, replace the duplex option.

237

.00

Paper did not reach the printer input sensor from the duplex unit.

Duplex jam access tray is not fully latched. Printer PTO not driving the duplex feed folls.Duplex feed system not working correctly.

237

.07

Duplex paper jam. There may be other jams in the paper path.

Duplex jam access tray is not fully latched. Printer PTO not driving duplex feed rolls. Duplex feed system not working correctly.

238

.00

Paper is covering one of the duplex sensors during a reset.

Media left in the duplex and Continue selected. Sensor is having mechanical or electrical problems.

238

.01

Duplex input sensor covered.

Media left in the duplex and Continue selected. Sensor is having mechanical or electrical problems.

2-82 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 238 Sub code .02 Description Duplex exit sensor covered. Possible causes Media left in the duplex and Continue selected. Sensor is having mechanical or electrical problems. Action Remove any sheets from the duplex option. Try the duplex option again. If it fails, try another duplex option, if available. If one is not available, replace the duplex option. Remove any sheets from the duplex option. Try the duplex option again. If it fails, try another duplex option, if available. If one is not available, replace the duplex option. Remove any sheets from the duplex option. Try the duplex option again. If it fails, try another duplex option, if available. If one is not available, replace the duplex option. Remove any sheets from the duplex option. Try the duplex option again. If it fails, try another duplex option, if available. If one is not available, replace the duplex option. Remove any sheets from the duplex option. Try the duplex option again. If it fails, try another duplex option, if available. If one is not available, replace the duplex option. Remove any sheets from the duplex option. Try the duplex option again. If it fails, try another duplex option, if available. If one is not available, replace the duplex option. Replace the duplex option.

238

.03

Duplex input and exit sensors covered.

Media left in the duplex and Continue selected. Sensor is having mechanical or electrical problems.

238

.04

Duplex doublefeed sensor covered.

Media left in the duplex and Continue selected. Sensor is having mechanical or electrical problems.

238

.05

Duplex doublefeed sensor covered.

Media left in the duplex and Continue selected. Sensor is having mechanical or electrical problems.

238

.06

Duplex doublefeed and exit sensors covered.

Media left in the duplex and Continue selected. Sensor is having mechanical or electrical problems.

238

.07

Duplex doublefeed, input, and exit sensors are covered.

Media left in the duplex and Continue selected. Sensor is having mechanical or electrical problems.

239

.00

Feed error in duplex unit.

Mechanical feed error due to belt slipping. Timing error due to feed system. Mechanical feed error due to belt slipping. Timing error due to feed system. Mechanical feed error due to belt slipping. Timing error due to feed system.

239

.01

Jam declared by a smart device. Immediate stop.

Replace the duplex option.

239

.02

Jam declared by a smart device. Homing allowed stop.

Replace the duplex option.

Diagnostic information

2-83

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 239 Sub code .03 Description Duplex did not send Device Controls response. Duplex did not send Input Device Ready response. Duplex did not send Page In Output Device response. Failed the last page of a staple job. Possible causes Mechanical feed error due to belt slipping. Timing error due to feed system. Mechanical feed error due to belt slipping. Timing error due to feed system. Mechanical feed error due to belt slipping. Timing error due to feed system. Mechanical feed error due to belt slipping. Timing error due to feed system. Mechanical feed error due to belt slipping. Timing error due to feed system. Action Replace the duplex option.

239

.04

Replace the duplex option.

239

.05

Replace the duplex option.

239

.06

Replace duplex option.

239

.07

Engine never sent Select OUtput Device to the duplex unit because the page leaving the duplex never sent Select Input Device. Engine never saw Input Source Read on a page to be picked from the duplex unit that is waiting on a page to pass the input sensor. Sheet picked from duplex never made it to the input sensor. Slow or delayed feed from the duplex unit. Paper jam near tray 1 Not applicable to tray 1 Not applicable to tray 1 Failed to pick from tray 1

Replace the duplex option.

239

.08

Mechanical feed error due to belt slipping. Timing error due to feed system.

Replace the duplex option.

239

.11

Mechanical feed error due to belt slipping. Timing error due to feed system. Input sensor not working correctly.

Check duplex sensor cables for correct installation. If no problem is found with the cables, replace the duplex option.

241 241 241 241

.00 .04 .05 .06

Paper jam around autocompensator, faulty motor cable, faulty motor, autocompensator gear bind, failed controller card. Paper jam around autocompensator, faulty motor cable, faulty motor, autocompensator gear bind, or failed controller card. Paper jam around autocompensator, faulty motor cable, faulty motor, autocompensator gear bind, or failed controller card.

Check for jam in tray. Check for overloaded tray. Check pick assembly and controller card. Check for jam in tray. Check pick assembly and controller card. Check for jam in tray. Check pick assembly and controller card.

241

.07

DC feed autocompensator stalled on a pick Received lots of dc feed interrupts before losing them.

241

.08

2-84 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 241 Sub code .09 Description Page did not reach input sensor. Possible causes If source is tray 1, possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor. Action Fan media. Turn media over. Reduce amount of media loaded in tray 1. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page A-105. Fan media. Turn media over. Reduce amount of media loaded in tray 1. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Fan media. Turn media over. Reduce amount of media loaded in tray 1. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Fan media. Turn media over. Reduce amount of media loaded in tray 1. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105.

241

.10

Page was not properly picked from tray 1.

Failure to feed possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past the fill line.

241

.11

Page was not properly picked from tray 1.

Failure to feed possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past the fill line.

241

.12

Page was not properly picked from tray 1.

Failure to feed possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past the fill line.

241 241

.13 .14

Not applicable to tray 1 Page was not properly picked from MPT, tray 1, or feeder Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor Fan media. Turn media over. Reduce amount of media loaded in tray 1. Replace the pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Clear any paper jams. Fan media.

241

.15

Late feed from a tray interfered with the pick retry

Staging of paper in tray 1.

Diagnostic information

2-85

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 241 Sub code .16 Description Failed to feed from tray 1. Pages in the paper path have been flushed to the output bin. Not applicable to tray 1. Paper jam near tray 2. Paper jam. Failed pass thru sensor. Fault reported by options tray 2: Paper jam Motor or motor cable failure Sensor failure Clear paper jam. Check sensor. Clear all jams. Check motor cables. Check and/or replace tray motor. Check and/or replace sensor(s). Replace entire option. Clear all jams. Check motor cables. Check/replace tray motor. Check and/or replace sensor(s). Replace entire option. Clear all jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check and/or replace input sensor. Possible causes Paper jam Worn pick tires. Action

241 242

.17 .00

242

.02

Jam declared by a smart device. Immediate stop.

242

.03

Jam declared by a smart device. Homing allowed stop.

Fault reported by options tray 2: Paper jam Motor failure Sensor failure

242

.04

Option tray pass thru sensor never became covered.

Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor If source is tray 3, possible cause include: Paper path bind when feeding from tray 2 though tray 1 Damaged PTO shaft Paper jam or failed sensor.

242

.05

Option tray pass thru sensor never became uncovered. Failed to pick from tray 2

Clear all jams. Check/replace pass thru sensor. Check for jam in tray. Check pick assembly and controller card.

242

.06

Paper jam around autocompensator Faulty motor cable Faulty motor Autocompensator gear bind Failed controller card.

242

.10

Failed to feed from tray 2

Failed to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor

Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor.

2-86 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 242 Sub code .13 Description Paper over tray 2 pass thru sensor on warm-up. Possible causes Paper left in path Failed pass thru sensor Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past the fill line Failed pass thru sensor Tray removed Sensors faulty Action Clear media jams. Check/replace pass thru sensor. Clear media jams. Replace pick tires. Check/replace input sensor.

242

.16

Failed to feed from tray 2. Pages in the paper path have been flushed to the output bin.

242

.17

One or more trays located above the source tray as been removed. Paper jam near tray 3

Reinstall tray. Check sensors.

243

.00

Paper jam Failed pass thru sensor Fault reported by options tray 3: Paper jam Motor or motor cable failure Sensor failure

Clear media jam. Check sensor. Clear all media jams. Check motor cables. Check/replace tray motor. Check/replace sensor(s). Replace entire option. Clear all media jams. Check/replace tray motor. Check/replace sensor(s). Replace entire option.

243

.02

Jam declared by smart device. Immediate stop.

243

.03

Jam declared by smart device. Homing allowed to stop

Fault reported by options tray 3: Paper jam Motor failure Sensor failure Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor

243

.04

Option tray pass thru sensor never became covered.

Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor. Check PTO shaft. Check all media jams. Check/replace pass thru sensor. Check for jam in tray. Check pick assembly and controller card.

243

.05

Option tray pass thru sensor never became uncovered. Failed to pick from tray 3

Paper jam Failed sensor Paper jam around autocompensator Faulty motor cable Faulty motor Autocompensator gear bind Failed controller card

243

.6

Diagnostic information

2-87

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 243 Sub code .10 Description Fail to feed from tray 3 Possible causes Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor Paper left in path Failed pass thru sensor Action Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor. Clear media jams. Check/replace pass thru sensor.

243

.13

Paper over tray 3 pass thru sensor on warm-up.

243

.15

Late feed from a tray interfered with the pick retry. Failed to feed from tray 3. Pages in the paper path have been flushed to the output bin. Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed pass thru sensor Tray removed Sensors faulty Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor. Reinstall tray. Check sensors.

243

.16

243

.17

One or more trays located above the source tray have been removed. Paper jam near tray 4.

244

.00

Tray removed Sensors faulty Fault reported by options tray 4: Paper jam Motor or motor cable failure Sensor failure

Clear media jams. Check sensor. Clear all media jams. Check motor cables. Check/replace tray motor. Check/replace sensor(s). Replace entire option. Clear all media jams. Check motor cables. Check/replace tray motor. Check/replace sensor(s). Replace entire option.

244

.02

Jam declared by a smart device. Immediate stop.

244

.03

Jam declared by a smart device. Homing allowed to stop.

Fault reported by options tray 4: Paper jam Motor failure Sensor failure

244

.04

Option tray pass thru sensor never became covered.

Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor If source is tray 5, possible causes include: Paper path bind when feeding from tray 2 through tray 1 Damaged PTO shaft.

Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor. Check PTO shaft.

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 244 Sub code .05 Description Option tray pass thru sensor never became uncovered. Failed to pick from tray 4 Possible causes Paper jam Failed sensor Paper jam around autocompensator Faulty motor cable Faulty motor Autocompensator gear bind Failed controller card Action Clear all jams. Check/replace pass thru sensor. Check for jam in tray. Check pick assembly and controller card.

244

.06

244

.10

Failure to feed from tray 4.

Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor Paper left in path. Failed pass thru sensor

Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor. Clear media jams. Check/replace pass thru sensor.

244

.13

Paper over tray 4 pass thru sensor on warm-up.

244

.15

Late feed from a tray interfered with the pick retry. Failed to feed from tray 4. Pages in the paper path have been flushed to the output bin.

244

.16

Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Could also be a failed pass thru sensor Tray removed Sensors faulty

Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor. Reinstall the tray. Check sensors.

244

.17

One or more trays location above the source tray have been removed. Paper jam near tray 5.

245

.00

Paper jam Failed pass thru sensor Fault reported by options tray 5: Paper jam Motor or motor cable failure Sensor failure

Clear media jam. Check sensor. Clear all media jams. Check motor cables. Check/replace tray motor. Check/replace sensor(s). Replace entire option. Clear all media jams. Check motor cables. Check/replace tray motor. Check/replace sensor(s). Replace entire option.

245

.02

Jam declared by a smart device. Immediate stop.

245

.03

Jam declared by a smart device. Homing allowed to stop.

Fault reported by options tray 5: Paper jam Motor failure Sensor failure

Diagnostic information

2-89

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 245 Sub code .04 Description Option tray pass thru sensor never became covered. Possible causes Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor Paper jam Failed sensor Paper jam around autocompensator Faulty motor cable Faulty motor Autocompensator gear bind Failed controller card Action Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor. Clear all jams. Check/replace pass thru sensor. Check for jam in tray. Check pick assembly and controller card.

245

.05

Option tray pass thru sensor never became uncovered. Failed to pick from tray 5

245

.06

245

.10

Failure to feed from tray 5.

Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Failed sensor Paper left in path. Failed pass thru sensor

Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor. Clear media jams. Check/replace pass thru sensor.

245

.13

Paper over tray 5 pass thru sensor on warm-up.

245

.15

Late feed from a tray interfered with the pick retry. Failed to feed from tray 5. Pages in the paper path have been flushed to the output bin. Failure to feed. Possible causes include: Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Could also be a failed pass thru sensor Tray removed Sensors faulty Clear media jams. Replace pick tires. See Integrated tray autocompensator pick roll assembly removal on page 4-105. Check/replace input sensor. Reinstall the tray. Check sensors.

245.1 6

.16

245

.17

One or more trays location above the source tray have been removed. Paper jam near the multipurpose feeder. Option tray pass thru sensor never became covered. Option tray pass thru sensor never became uncovered.

250 250

.00 .01

250

.02

2-90 Service Manual

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 250 Sub code .06 Description Page did not reach input sensor. Possible causes Paper jam around the multipurpose tray. Action Check for jam in tray. Check pick assembly and controller card. Check for jam in tray. Check pick assembly and controller card. Check for jam in tray. Check pick assembly and controller card. Check for jam in tray. Check the pick assembly and controller card. Check for jam in tray. Check pick assembly and controller card. Check for jam in tray. Check the pick assembly and controller card.

250

.07

Page was not properly picked from multipurpose feeder. Page was not properly picked from multipurpose feeder. Page was not properly picked from multipurpose feeder. Page was not properly picked from multipurpose feeder. Failed to feed from multipurpose feeder. Pages in the paper path have been flushed to the output bin. Paper jam near the envelope feeder. Jam declared by a smart device. Immediate stop. Jam declared by a smart device. Homing allowed stop. Envelope feeder pass thru sensor never became uncovered. Envelope feeder pass thru sensor never became covered. Failed to pick from the envelope feeder.

Paper jam around the multipurpose feeder.

250

.08

Paper jam around the multipurpose feeder.

250

.09

Paper jam around the multipurpose feeder.

250

.10

Paper jam around the multipurpose feeder.

250

.11

Paper jam around the multipurpose feeder.

260 260 260

.00 .01 .02

260

.05

260

.06

260

.07

Paper jam around the envelope feeder.

Remove feeder and clear jam. Replace feeder. Remove feeder and clear jam. Replace feeder. Remove feeder and clear jam. Replace feeder. Remove feeder and clear jam. Replace feeder.

260

.10

Page did not reach input sensor from envelope feeder. Page did not reach input sensor from envelope feeder. Page did not reach input sensor from envelope feeder.

Paper jam around envelope feeder

260

.11

Paper jam around envelope feeder

260

.12

Paper jam around envelope feeder

Diagnostic information

2-91

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 260 260 Sub code .13 .14 Description Paper in envelope feeder on warm-up. Page was not properly picked from envelope feeder. Page was not properly picked from envelope feeder. Failed to feed from envelope feeder. Pages in the paper path have been flushed to the output bin. Static jamADF Interval Sensor Paper jam around envelope feeder. Remove feeder and clear jam. Replace feeder. Remove feeder and clear jam. Replace feeder. Remove feeder and clear jam. Replace feeder. Possible causes Action

260

.15

Paper jam around envelope feeder.

260

.16

Paper jam around envelope feeder.

290

.00

The paper may be stuck in the ADF at or over the interval sensor. Interval sensor may be malfunction. The ADF attempted to stage a page but the leading edge of the page did not reach the interval sensor. The leading edge of the page reached the interval sensor but did not reach the first scan sensor.

Go to 290.00 Error code service check on page 2-96.

290

.01

ADF Pickup Jam.

Go to 290.01 Error code service check on page 2-98. Check for proper operation of the first scan sensor. If the sensor is opening properly and no other problem is found, go to 290.02 Error code service check on page 2-100. Check for any media or obstruction over the first scan sensor. If no problem is found, go to 290.10 Error code service check on page 2-102. Check for any media or obstruction over the second scan sensor. If no problem is found, go to 291.00 Error code service check on page 2-104. Go to 291.01 Error code service check on page 2-105. Clear any media from the ADF and close the cover. If this does not fix the problem, then go to 291.02 Error code service check on page 2-106. Clear any paper from the ADF and close the cover. If this does not fix the problem, then go to 292.00 Error code service check on page 2-107.

290

.02

ADF Feed Jam.

290

.10

Static jamFirst Scan Sensor.

Paper may be stuck in the ADF at the first scan sensor or the first scan sensor may be malfunctioning.

291

.00

Static JamSecond Scan Sensor.

Paper may be stuck in the ADF at the second scan sensor or the second scan sensor is not operating properly.

291

.01

First ADF Scan Sensor Jam.

The second sensor detected the leading edge of the paper but never detected the training edge. The first scan sensor detected the trailing edge of the paper. The first scan sensor has detected the trailing edge of the page, but the second scan sensor did not detect the leading edge of the page. The ADF cover was opened while the ADF was scanning.

291

.02

Second ADF Scan Sensor

292

.00

ADF Cover Open Jam

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User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 293 Sub code .00 Description Paper Missing Jam Possible causes An attempt was made to force an ADF scan, by a custom job, page level jam recovery, or so on, with no paper in the ADF input tray or the paper was removed from the ADF input tray just as it was being staged. The paper present sensor may be malfunctioning. The page is stuck in the ADF at the exit sensor or the exit sensor is malfunctioning. Action Make sure the media is loaded in the ADF when starting an ADF scan. If no problem is found, go to 293 Error code service check on page 2-108. Check for any jammed pages in the ADF and remove. If the problem persists, go to 294.00 Error code service check on page 2-109. Verify that the exit sensor is operating properly. If the problem persists and the exit sensor seems to be operating properly, go to 294.01 Error code service check on page 2-110. Verify the exit sensor is operating properly. If the problem persists and the exit sensor seems to be operating properly, go to 294.02 Error code service check on page 2-112. Verify that the exit sensor is operating properly. If the problem persists and the exit sensor seems to be operating properly, go to 294.03 Error code service check on page 2-113. Clean the flatbed white cushion. See Cleaning the scanner glass, cushions, and strips on page 6-2. Clean the scanner glass for both the flatbed and ADF. See Cleaning the scanner glass, cushions, and strips on page 6-2. Check the cables on the rear of the scanner to make sure they are plugged in and fastened securely. If no problem is found with the cables, go to 298.01 Error code service check model 500S on page 2-115.

294

.00

Static JamADF Exit Sensor

294

.01

ADF Eject Jam

The exit sensor may not be operating properly or malfunctioning.

294

.02

ADF Exit Jam Sensor Off

The exit sensor may not be operating properly or malfunctioning.

295

.03

ADF Exit Jam Sensor On

The exit sensor may not be operating properly or malfunctioning.

287

.13

Clean Scanner Backing Strip

The flatbed white cushion inside the ADF is dirty.

297

.14

Clean Scanner Glass

The scanner document glass is dirty.

298

.01

Scanner MissingFront Side Cable Unplugged

One of the cables on the rear of the scanner is unplugged or loose.

Diagnostic information

2-93

User attendance messagespaper jams and paper handling errors (2xx.xx)

Code 298 Sub code .02 Description Scanner MissingRear Side Cable Unplugged Possible causes One of the cables on the rear of the scanner is unplugged or loose. Action Check the cables on the rear of the scanner to make sure they are plugged in and fastened securely. If no problem is found with the cables, go to 298.02 Error code service check on page 2-115.

2-94 Service Manual

Service checks
Anytime the system board is replaced, the Configuration ID must be reset in NVRAM. Go to Configuration ID on page 3-19. Review the following information before performing any service checks.

Paper feed problems (especially paper jams): Go to Display Log on page 3-21 and check the printer
event log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option. Paper feed problems with error message: Use the Sub error codes for 8xx, 9xx, and 2xx error codes on page 2-13 to help diagnose the problem. Print quality problems: Go to Printing Quality Pages on page 3-7 and print a test page to help diagnose problems before changing any settings or working on the printer. Use the resident diagnostics test provided to help isolate a problem before taking the machine apart or removing any options.

202.03 Error code service check

The spring on the narrow media sensor flag may not be working correctly. When the sensor flag is made, it does not return to the correct position. FRU 1 Fuser narrow media sensor flag and spring Action Remove the fuser narrow media sensor. See Fuser narrow media sensor removal on page 4-88. Inspect the flag and spring. If there is damage or the flag and spring do not operator correctly, replace the fuser narrow media sensor flag and spring. See Fuser narrow media flag and spring removal on page 4-90. If this does not correct the problem, go to step 2. Replace the fuser assembly. See Fuser assembly removal on page 4-79.

Fuser assembly

202.06 Error code service check

The spring on the fuser exit sensor flag may not be working correctly. When the sensor flag is made, it does not return to the correct position. FRU 1 Fuser exit sensor flag and spring Action Remove the fuser exit sensor . See ). Inspect the flag and spring. If there is damage or the flag and spring do not operator correctly, replace the fuser exit sensor flag and spring. See Fuser exit sensor flag and spring removal on page 4-83. If this does not correct the problem, go to step 2. Replace the fuser assembly. See Fuser assembly removal on page 4-79.

Fuser assembly

Diagnostic information

2-95

290.00 Error code service check

Static jamADF interval sensor (A).

A
Note: Before starting this service check, make sure the interval sensor cable is correctly installed. FRU 1 ADF Action Check for any signs of paper or other debris that might be present in the ADF assembly over the interval sensor. If nothing found, go to step 2. Enter the Diagnostic Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS and then select Sensor Tests. Check the interval sensor for correct operation. Note: You can check the interval sensor by putting a sheet of paper over the sensor. This is easier to perform by first removing the pick arm assembly. If the sensor fails the test, go to step 3. Check to make sure the interval sensor cable is correctly installed at the sensor and atCN10 on the motor driver card. If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4. Turn the power off and disconnect CN10 on the motor driver card. Measure the voltages at the board:
Interval sensorreflective type (normally closed) Connector CN10 (motor driver card) CN10Pin 7 CN10Pin 8 CN10Pin 9 0 V dc +5.0 V dc +5.0 V dc

Interval sensor

Interval sensor cable (interval sensor to CN10 on the MDC card) Motor driver card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If correct go to step 5.

2-96 Service Manual

FRU

Action Turn the power off and reconnect CN10 to the motor driver card. Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (paper over the sensor).
Interval sensorreflective type (normally closed) Connector CN10 (motor driver card) Pin number CN10Pin 7 CN10Pin 8 CN10Pin 9 Sensor closed (uncovered 0 V dc +0.03 V dc +5.0 V dc Sensor open (covered) 0 V dc +5.0 V dc +5.0 V dc

Interval sensorelectrical checks

Note: All voltages are approximate values.

If the voltages are incorrect replace the interval sensor. If this does not fix the problem, replace the complete ADF assembly. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

Diagnostic information

2-97

290.01 Error code service check

ADF pickup jam. Note: Before starting this service check, make sure the interval sensor (A) cable is correctly installed.

A
FRU 1 Pickup arm assembly Action Check to make sure the pickup arm is correctly installed. If not installed correctly, reinstall properly. If installed correctly, check the pickup arm assembly for any signs of damage or broken parts. If a problem is found, replace the pickup arm assembly. Check the pickup arm solenoid springs to make sure they are correctly attached to the jam removal knob pulley. If not installed correctly, reinstall. If installed correctly, go to step 3. Check for any signs of broken or damaged pickup arm solenoid assembly springs. If either spring is broken or damaged, replace the solenoid assembly which contains both springs. See ADF pick assembly removal on page 4-7. If no problem is found, go to step 4. Turn the power off, disconnect CN5 on the motor driver card. Measure the resistance between C5-1 and CN5-2. The resistance should measure approximately 41.0 ohms. If correct, go to step 5. If incorrect, disconnect the solenoid from the solenoid cable on the front side of the ADF near the solenoid, and measure the resistance between pins 1 and 2 on the cable attached to the solenoid. The resistance should measure approximately 41.0 ohms. If incorrect, replace the solenoid assembly. If correct, replace the ADF assembly. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4. Reconnect CN5 to the motor driver card, and measure the voltage at CN5-1 and CN5-2. The voltage should measure approximately +25.0 V dc. If incorrect, replace the motor driver card. If correct, go to step 6.

Pickup arm solenoid springs

Pickup arm solenoid springs

Pickup arm solenoid

Motor driver card

2-98 Service Manual

FRU

Action Check the ADF feed motor for proper operation. Turn the power off, disconnect CN2 on the motor driver card, and measure the voltages on CN2.
ADF feed motor Connector CN2 (motor driver card) Pin number CN2Pin 1 CN2Pin 2 CN2Pin 3 CN2Pin 4 CN2Pin 5 CN2Pin 6 Static +1.5 V dc +1.5 V dc +1.5 V dc +1.5 V dc +1.5 V dc +1.5 V dc Operating +24 V dc +24 V dc +24 V dc +24 V dc +24 V dc +24 V dc

ADF feed motor

Note: All voltages are approximate values.

If the voltages are incorrect, replace the motor driver card. If incorrect, turn the power off, reconnect the motor cable to CN2, and measure the voltages on the scan motor connector. If incorrect, replace the scan motor. If correct, go to step 7.

Scan motor belt

Check the scan motor drive belt for any signs of wear or damage or the belt off the gear. If the belt is off the gear, reinstall. If the belt is worn or damaged, replace the belt. If no problem is found replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4. Turn the power off and reconnect CN10 to the motor driver card. Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (paper over the sensor).
Interval sensorreflective type (normally closed) Connector CN10 (motor driver card) Pin number CN10Pin 7 CN10Pin 8 CN10Pin 9 Sensor closed (uncovered 0 V dc +0.03 V dc +5.0 V dc Sensor open (covered) 0 V dc +5.0 V dc +5.0 V dc

Interval sensorelectrical checks

Note: All voltages are approximate values.

If the voltages are incorrect replace the interval sensor. If this does not fix the problem, replace the complete ADF assembly. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

Diagnostic information

2-99

290.02 Error code service check

ADF feed jam.

A
Note: Before starting this service check, make sure the first scan sensor (A) cable is correctly installed. FRU 1 ADF Action Check for any signs of paper or other debris that might be present in the ADF assembly over the interval sensor but short of the first scan sensor. Remove any media found in the ADF, and retry by running the scanner feed tests. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Feed Tests. If the paper fails to reach the first scan sensor, go to step 2. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the first scan sensor for correct operation. Note: Check the first scan sensor by manually feeding a sheet of paper through the ADF and checking the sensor for correct operation. If the sensor fails the test, go to step 3. Check to make sure the interval sensor cable is correctly installed at the sensor CN10 on the motor drive card. If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4. Turn the power off, and disconnect CN10 on the motor driver card. Measure the voltages in the table below:
First scan sensorreflective type (normally closed) Connector CN10 (motor driver card) CN10Pin 10 CN10Pin 11 CN10Pin 12 0 V dc +5 V dc +5 V dc

First scan sensor

First scan sensor cable (first scan sensor to CN10 on the MDC card) Motor driver card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If correct, go to step 5.

2-100 Service Manual

FRU

Action Turn the power off and reconnect CN10 to the motor driver card. Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (paper over the sensor).
First scan sensor Connector CN10 (motor driver card) Pin number CN10Pin 10 CN10Pin 11 CN10Pin 12 Sensor closed (uncovered) Sensor open (covered) 0 V dc +5.0 V dc +0.03 V dc 0 V dc +5.0 V dc +5.0 V dc

First scan sensor electrical checks

Note: All voltages are approximate values.

If the voltages are incorrect, replace the first scan sensor. If the voltages are correct, go to step 6.

ADF scan motor

Check the ADF scan motor for proper operation. Turn the power off, disconnect CN3 on the motor driver card, and measure the voltages on CN3 on the card.
ADF scan motor Connector CN3 (motor driver card) Pin number CN3Pin 1 CN3Pin 2 CN3Pin 3 CN3Pin 4 CN3Pin 5 CN3Pin 6 Static +1.5 V dc +1.5 V dc +1.5 V dc +1.5 V dc +1.5 V dc +1.5 V dc Operating +24 V dc +24 V dc +24 V dc +24 V dc +24 V dc +24 V dc

Note: All voltages are approximate values.

If the voltages are incorrect, replace the motor driver card. If correct, turn the power off, reconnect the motor cable to CN3, and measure the voltages on the scan motor connector (see the table above). If correct, go to step 7.

Scan motor belt

Check the scan motor drive belt for any signs of wear or damage or the belt is off the gear. If the belt is off the gear, reinstall. If the belt is worn or damaged, replace the belt. If no problem is found, Replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, is necessary to perform the scanner registration. See Scanner registration on page 4-4.

Diagnostic information

2-101

290.10 Error code service check

Static jamfirst scan sensor (A)

A
Note: Before starting this service check, make sure the first scan sensor cable is correctly installed. FRU 1 ADF Action Check for any signs of paper or other debris that might be present in the ADF assembly over the first scan sensor. Remove any media found over the sensor, and retry by running the scanner feed tests. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Feed Tests. If the media jams over the first scan sensor, go to step 2. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the first scan sensor for correct operation. Note: Check the first scan sensor by manually feeding a sheet of paper through the ADF and checking the sensor for correct operation. If the sensor fails the test, go to step 3. Check to make sure the first scan cable is correctly installed at the sensor CN10 on the motor drive card. If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4. Turn the power off, and disconnect CN10 on the motor driver card. Measure the voltages in the table below:
First scan sensorreflective type (normally closed) Connector CN10 (motor driver card) CN10Pin 10 CN10Pin 11 CN10Pin 12 0 V dc +5 V dc +5 V dc

First scan sensor

First scan sensor cable (first scan sensor to CN10 on the MDC card) Motor driver card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If correct, go to step 5.

2-102 Service Manual

FRU

Action Turn the power off, and reconnect CN10 to the motor driver card. Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (paper over the sensor).
First scan sensor Connector CN10 (motor driver card) Pin number CN10Pin 7 CN10Pin 8 CN10Pin 9 Sensor closed (uncovered) +0 V dc +0.03 V dc +5.0 V dc Sensor open (covered) 0 V dc +5.0 V dc +5.0 V dc

First scan sensor electrical checks

Note: All voltages are approximate values.

If the voltages are incorrect, replace the first scan sensor. If this does not fix the problem, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

Diagnostic information

2-103

291.00 Error code service check

Static jamsecond scan sensor (A).

A
Note: Before starting this service check, make sure the second scan sensor cable is correctly installed. FRU 1 ADF Action The media is jammed or stuck in the ADF at the second scan sensor. Check for any signs of paper or other debris that might be present or jammed in the ADF assembly around the second scan sensor. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the second scan sensor for correct operation. Note: To manually activate the sensor, you can either open the jam removal tray (it is necessary to defeat the jam tray sensor by placing a piece of paper in the sensor to turn off the jam tray message on the display), or you can manually feed a piece of paper through the ADF. If the sensor fails the test, go to step 3. Check to make sure the first scan cable is correctly installed at the sensor CN9 on the SCC (scanner control card in the ADF). If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4. Turn the power off, and disconnect CN9 on the motor driver card. Measure the voltages in the table below:
First scan sensorreflective type (normally closed) Connector CN9 (motor driver card) CN9Pin 4 CN9Pin 5 CN9Pin 6 0 V dc +5 V dc +5 V dc

Second scan sensor

Second scan sensor cable (second scan sensor to CN9 on the MDC card) Motor driver card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If correct, go to step 5.

2-104 Service Manual

FRU

Action Turn the power off, and reconnect CN9 to the motor driver card. Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (sensor flag activated).
Second scan sensor Connector CN9 (motor driver card) Pin number CN9Pin 4 CN9Pin 5 CN9Pin 6 Sensor closed +0 V dc +1.16 V dc +5.0 V dc Sensor open 0 V dc +1.16 V dc +0.15 V dc

Second scan sensor electrical checks

Note: All voltages are approximate values.

If the voltages are incorrect, replace the second scan sensor. If this does not fix the problem, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

291.01 Error code service check

First ADF scan sensor (A) jam.

A
Note: Before starting this service check, make sure the first scan sensor cable is correctly installed. FRU 1 ADF Action The leading edge of the media was detected by the first scan sensor, but never detected by the trailing edge. Clear any media that may be in the ADF. Enter Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, load some sheets of paper in the ADF paper tray, and select Feed Tests. If the error continues at or near the same point, go to step 2. Check the area around the first scan sensor for anything that might cause the stop or jam prior to exiting the first scan sensor. If the problem continues and you cannot find anything causing this jam, replace the complete ADF assembly. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

Area around the first scan sensor

Diagnostic information

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291.02 Error code service check

Second ADF scan sensor (A) jam.

A
Note: Before starting this service check, make sure the sensor cable is correctly installed. FRU 1 ADF Action The second scan sensor has detected the leading edge of the sheet but did not detect the training edge. The first scan sensor detected the leading edge. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Feed Tests. Load several sheets through the ADF to check for any jams prior to the second scan sensor. If the jam is persistent, go to Step 2. Check the ADF feed gears, pulleys, and hardware for any signs of binding, broken, or damaged parts. If any problems are found, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4. Note: To help isolate a problem with the ADF feed system you can run the Feed Test from the SCANNER TESTS in the Diagnostics Menu. Put several sheets of media in the ADF tray, and observe the gears, motor, belts, and other hardware for any signs of a malfunction that might cause the media not to reach the second scan sensor. Check to make sure the second scan sensor cable is correctly installed at the sensor at CN9 on the MDC (motor driver card in the ADF). If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4.

ADF feed gears and hardware

Second scan sensor cable (second scan sensor to CN9 on the MDC card)

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FRU

Action Turn the power off, and disconnect CN9 on the motor driver card. Measure the voltages in the table below:
Second scan sensorreflective type (normally closed) Connector CN9 (motor driver card) CN9Pin 4 CN9Pin 5 CN9Pin 6 0 V dc +5 V dc +5 V dc

Motor driver card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If correct, go to step 5.

Second scan sensor electrical checks

Turn the power off and reconnect CN9 to the motor driver card. Measure the voltages in the table below with the sensor in normal operations (sensor closed) and with the sensor open (sensor flag activated).
Second scan sensorinterrupter type (normally closed) Connector CN9 (motor driver card) Pin number CN9Pin 4 CN9Pin 5 CN9Pin 6 Sensor closed 0 V dc +1.16 V dc +5.0 V dc Sensor open 0 V dc +1.16 V dc +0.15 V dc

Note: All voltages are approximate values.

If the voltages are incorrect, replace the second scan sensor. If this does not fix the problem, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

292.00 Error code service check

ADF cover open jam. FRU 1 ADF upper top cover Action Check the ADF upper top cover to make sure it closes properly and does not come loose or pop up while the ADF is scanning.

Diagnostic information

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293 Error code service check

Paper missing jam. Note: Before starting this service check, make sure the sensor cable is correctly installed. FRU 1 ADF Action Check the ADF for any media that might be jammed in the ADF. Turn the MFP off and then back on. Feed several sheets of media through the ADF. If the error still occurs, go to step 2. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the paper present sensor for correct operation by inserting a sheet of paper into the ADF paper tray to activate the paper present sensor. If the sensor does not operate properly, go to step 3. Measure the voltages shown in the table below:
Paper present sensorinterrupter type (normally closed) Connector CN10 (motor driver card) Pin number CN10Pin 4 CN10Pin 5 CN10Pin 6 Sensor closed 0 V dc +4.3 V dc +1.6 V dc Sensor open 0 V dc +0.25 V dc +1.6 V dc

Paper present sensor

Paper present cable Motor driver card

Note: All voltages are approximate values.

If the voltages are incorrect, turn the power off, disconnect the cable attached to CN10 on the motor driver card, and measure the voltages in the table below:
Paper present sensorinterrupter type (normally closed) Connector CN10 (motor driver card) CN10Pin 4 CN10Pin 5 CN10Pin 6 0 V dc +4.3 V dc +5 V dc

Note: All voltages are approximate values.

If the voltages are incorrect, replace the motor driver card. If the voltages are correct, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

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294.00 Error code service check

Static jamADF exit sensor (A).

A
Before starting this service check, Check the ADF exit sensor cable for correct installation. FRU 1 ADFjammed media Action Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag. Remove any media or debris. If nothing is found, go to step 2. Check the exit sensor flag to make sure it operates freely and does not hang or bind. If the flag does not operate correctly and cannot be made to operate correctly, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4. If the flag operates correctly, go to step 3. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the ADF exit sensor for correct operation. Note: You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF. If the sensor fails the test, go to step 4. Turn the power off, and disconnect CN9 on the motor driver card. Measure the voltages in the table below:
Interval sensorinterrupter type (normally closed) Connector CN9 (motor driver card) CN9Pin 1 CN9Pin 2 CN9Pin 3 0 V dc +5 V dc +5 V dc

ADF exit sensor flag

ADF exit sensor

Motor driver card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If correct, go to step 5.

Diagnostic information

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FRU

Action Turn the power off, and reconnect CN9 to the motor driver card. Measure the voltages in the table below with the sensor in normal operation (sensor closed) and the sensor open (sensor flag activated).
ADF exit sensorinterrupter type (normally closed) Connector CN9 (motor driver card) Pin number CN9Pin 1 CN9Pin 2 CN9Pin 3 Sensor closed 0 V dc +1.16 V dc +5.0 V dc Sensor open 0 V dc +1.16 V dc +0.15 V dc

ADF exit sensorelectrical checks

Note: All voltages are approximate values.

If the voltages are incorrect, replace the ADF exit sensor. If this does not fix the problem, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

294.01 Error code service check

ADF eject jam. Note: Before starting this service check, make sure the ADF exit sensor (A) cable is installed correctly.

A
FRU 1 ADFjammed media Action Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag. Remove any media or debris. If nothing is found, go to step 2.

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7002-xxx

FRU

Action Check the exit sensor flag to make sure it operates freely and does not hang or bind. If the flag does not operate correctly and cannot be made to operate correctly, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4. If the flag operates correctly, go to step 3. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the ADF exit sensor for correct operation. Note: You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF. If the sensor fails the test, go to step 4. Turn the power off, and disconnect CN9 on the motor driver card. Measure the voltages in the table below:
Exit sensorinterrupter type (normally closed) Connector CN9 (motor driver card) CN9Pin 1 CN9Pin 2 CN9Pin 3 0 V dc +5 V dc +5 V dc

ADF exit sensor flag

ADF exit sensor

Motor driver card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If the error persists, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

Diagnostic information

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294.02 Error code service check

ADF exit jam sensor (A) off.

A
Note: Before starting this service check, make sure the sensor cable is installed correctly. FRU 1 ADFjammed media Action Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag. Remove any media or debris. If nothing is found, go to step 2. Check the exit sensor flag to make sure it operates freely and does not hang or bind. If the flag does not operate correctly and cannot be made to operate correctly, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4. If the flag operates correctly, go to step 3. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the ADF exit sensor for correct operation. Note: You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF. If the sensor fails the test, go to step 4. Turn the power off and disconnect CN9 on the motor driver card. Measure the voltages in the table below:
Interval sensorinterrupter type (normally closed) Connector CN9 (motor driver card) CN9Pin 1 CN9Pin 2 CN9Pin 3 0 V dc +5 V dc +5 V dc

ADF exit sensor flag

ADF exit sensor

Motor driver card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If the voltage is correct, go to step 5.

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7002-xxx

FRU

Action Turn the power off, and reconnect CN9 to the motor driver card. Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (sensor flag activated).
ADF exit sensorinterrupter type (normally closed) Connector CN9 (motor driver card) Pin number CN9Pin 1 CN9Pin 2 CN9Pin 3 Sensor closed 0 V dc +1.16 V dc +5.0 V dc Sensor open 0 V dc +1.16 V dc +0.15 V dc

ADF exit sensorelectrical checks

Note: All voltages are approximate values.

If the voltages are incorrect, replace the ADF exit sensor. If this does not fix the problem, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

294.03 Error code service check

ADF exit jam sensor on. This error generally indicates that the ADF exit sensor (A) is defective, exit sensor cable is open, or the voltages on the motor driver card at pins 1, 2, or 3 are incorrect.

A
Note: Before starting this service check, make sure the sensor cable is installed correctly. FRU 1 ADFjammed media Action Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag. Remove any media or debris. If nothing is found, go to step 2.

Diagnostic information

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FRU

Action Check the exit sensor flag to make sure it operates freely and does not hang or bind. If the flag does not operate correctly and cannot be made to operate correctly, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4. If the flag operates correctly, go to step 3. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the ADF exit sensor for correct operation. Note: You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF. If the sensor fails the test, go to step 4. Turn the power off and disconnect CN9 on the motor driver card. Measure the voltages in the table below:
Interval sensorinterrupter type (normally closed) Connector CN9 (motor driver card) CN9Pin 1 CN9Pin 2 CN9Pin 3 0 V dc +5 V dc +5 V dc

ADF exit sensor flag

ADF exit sensor

Motor driver card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If the voltage is correct, go to step 5.

ADF exit sensorelectrical checks

Turn the power off and reconnect CN9 to the motor driver card. Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (sensor flag activated).
ADF exit sensorinterrupter type (normally closed) Connector CN9 (motor driver card) Pin number CN9Pin 1 CN9Pin 2 CN9Pin 3 Sensor closed 0 V dc +1.16 V dc +5.0 V dc Sensor open 0 V dc +1.16 V dc +0.15 V dc

Note: All voltages are approximate values.

If the voltages are incorrect, replace the ADF exit sensor. If this does not fix the problem, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

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298.01 Error code service checkmodel 500S

Scanner missingfront side cable unplugged.This is the ADF CCD 36 pin ICC cable connected to the ADF CCD. FRU 1 ADF CCD cable Action Check the cable for correct connections to the flatbed interface connector on the rear of the flatbed scanner assembly and to the ADF CCD assembly. If incorrect, install the cable correctly. If correct, replace the following FRUs in the order shown: ADF CCD cable. Flatbed interconnect card. See Flatbed interconnect card removal on page 4-33 ADF CCD assembly. If ADF CCD assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

298.02 Error code service check

Scanner missingrear side cable unplugged. This is the MDC 36 pin ICC cable connected to the motor driver card. FRU 1 MDC cable Action Check the cable for correct connections to the flatbed interface connector on the rear of the flatbed scanner assembly and to the motor driver card. If incorrect, install the cable correctly. If correct, replace the following FRUs in the order shown: MDC cable. Flatbed interconnect card. See Flatbed interconnect card removal on page 4-33 Motor driver card.

842.xx Error code service check

Service Scannerscanner communications failure. FRU 1 Scanner control card to flatbed inteconnect card cable Motor drive card to flatbed interconnect card cable Motor driver card Flatbed interconnect card Action Check for correct installation of the scan control to flatbed interconnect card cable. Check for correct installation of the motor driver card to flatbed interconnect card cable. If the cables are good and are properly connected, replace the following FRUs in the order shown: Flatbed interconnect card assembly Motor driver card assembly

2 3

Diagnostic information

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843.xx Error code service check

Service Scannerflatbed mechanical failure Other symptoms may include a loud noise from between the flatbed and the printer unit, or a blue screen on the display. Note: Check for correct installation of the home sensor cable before proceeding with this service check. FRU 1 Flatbed scanner CCD drive shafts Flatbed CCD module assembly ribbon cable Flatbed CCD module assembly Action Check to make sure that both of the CCD drive shafts are correctly installed. If correct, go to step 2. Check to make sure that the flatbed CCD module assembly is connected correctly to both the CCD module and J2 on the scanner control card. If correct, go to step 3. Check the flatbed CCD assembly for any signs of damage and for proper mechanical operation. If any problems are found, replace the flatbed CCD assembly. If the flatbed CCD assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4. Check for correct installation of the CCD scan motor cable to both the motor and to the flatbed interface card at CN2. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Feed Tests.If the motor does not turn during the scanner Feed Test, check for any signs of binds or mechanical problems. Repair as necessary. If no problem is found, go to step 5. Check to make sure that the home sensor cable is correctly installed to both the home sensor and to CN4 on the flatbed interface card. Check for correct operation of the home sensor. If it does not operate correctly, replace the FRUs in the following order: Flatbed interface card. See Flatbed interconnect card removal on page 4-33. Flatbed home sensor. See Home sensor removal on page 4-46. If the problem persists, go to step 6.

Flatbed CCD scan motor/ cable Flatbed interface card

Flatbed home sensor cable Flatbed home sensor Flatbed interface card

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FRU

Action Check for mechanical interference with the flatbed CCD assembly and the metal locating bracket. Remove the glass slit. See Scanner flatbed glass holder assembly removal on page 4-50. The bracket is located near the home position, to the left side of the flatbed. 1. Move the flatbed CCD assembly a few inches to the right of home. 2. Bend the bracket upwards 12 mm.

Mechanical interference with the flatbed CCD assembly

3. Move the flatbed CCD assembly back to the home position and check for clearnace between the bracket and the edge of the flatbed CCD assembly.

If this does not fix the problem, got to step 7.

Flatbed scanner assembly

If the 843.00 error code continues to be displayed, replace the complete flatbed scanner assembly. See Flatbed scan assembly removal on page 4-38. Note: If the flatbed scanner assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

845.00 Error code service check

Service Scannerthis error indicates a failure of the image processing ASIC on the scanner control card. FRU 1 Scanner control card Action Replace the scanner control card. See Scanner control card removal on page 4-48.

Diagnostic information

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848.00 Error code service check

Service scannerModem/Config ID mismatch
This error indicates that no modem is installed on a modem MFP. FRU 1 Modem Action Install a modem.

848.01 Error code service check

Service scannerModem/Config ID mismatch. This error indicates that a mode is present on an MFP not configured to support a modem. FRU 1 Modem Action Remove the modem installed in the printer.

900.xx Error code service check

FRU 1 Printer POR System board Action Turn the printer off and on several times. If Error Code 900 continues to display, go to step 2. Turn the machine off and on several times, waiting a few minutes between power on and power off. If Error Code 900 continues to display, go to step 3. Restore factory defaults. See EP Defaults on page 3-20. This resets the non-critical areas of the user NVRAM. If Error Code 900 continues to display, go to step 4. With Error Code 900 displayed, press and 2. Record the complete list of Sub Error Codes on the display, then call your next level of support or call Toshba.

Factory defaults

Sub error codes

900.90 Error code service check

Service scannerThis error indicates defective modem hardware. FRU 1 Modem Action Replace the modem.

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927.xx Fan service check

927.xx can be used for the main fan or the cartridge fan.

Main fan927.00, 927.01, and 927.03 through 927.07. Cartridge fan927.02 Main fan service check
Service tip: The main fan runs at full speed at the end of POR or when the printer is printing. It will only run half speed when the printer is in the Ready state and not printing. FRU 1 Main fan Action Check the main fan to make sure it is plugged into J4 on the system board. If the fan cable id correctly connected to J4, check the cable and the cable connector for any signs of damage. If damaged, replace the main fan assembly. See Main fan removal on page 4-111. If undamaged, go to step 2. Turn the printer off and check the main fan for any signs of blockage of the fan blades. If there is any sign of blockage, remove the blockage. Measure the voltage at J4-1 on the system board. The voltage should measure approximately +2.5 V dc. If incorrect, replace the main fan. See Main fan removal on page 4-111. If that does not fix the problem, replace the system board. See System board and inner shield removal model 500S" on page 4-131. Measure the voltage at J4-3. The voltage should measure +14.4 V dc with the fan running full and approximately 7.0 V dc when running half speed. If incorrect, replace the main fan. See Main fan removal on page 4-111. If this does not fix the problem, replace the system board. See System board and inner shield removal model 500S on page 4-131.

Main fan

Main fan blades turn during POR, then stop. Fan will not run when trying to print. Main fan System board Main fan blades do not turn

Cartridge fan service check

Error code 927.02 indicates a problem with the cartridge fan. FRU 1 Cartridge fan Cartridge fan Cartridge fan System board Action Check to make sure the cartridge is plugged into J5 on the system board. If properly plugged in, go to step 2. Check for any signs of blockage in the fan. If any is found, remove and retry the printer. If no problem is found, go to step 3. Replace the following FRUs in the order shown: Cartridge fan System board. See System board and inner shield removal model 500S on page 4-131.

2 3

Diagnostic information

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950.00 through 950.29 EPROM mismatch failure

Warning: When replacing any one of the following components:

Flatbed interconnect card (ICC) System board assembly Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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.

This error code indicates a mismatch between the operator panel board and the interface card. FRU 1 Interface card Operator panel board Action If the interface card been recently replaced, go to step 3. If the card has not been replaced go to step 2. If the operator panel board has been recently replaced, go to step 4. If the operator panel board has not been replaced, contact your next level of support. Replace the current interface card assembly with the original interface card assembly. See Interface card assembly removal on page 4-107. If the error remains, go to step 5. Replace the current operator panel board with the original operator panel board. See Operator panel right cover assembly removal on page 4-64. If the error persists, go to step 6. Replace the original interface card assembly with a new and not previously installed interface card assembly. If the error remains, contact your next level of support. Replace the original operator panel board with a new and not previously installed interface card assembly. If the error remains, contact your next level of support.

Interface card

Operator panel board

Interface card

Operator panel

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950.30 through 950.60 EPROM mismatch failure

Warning: When replacing any one of the following components:

Flatbed interconnect card (ICC) System board assembly Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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.

Note: Before proceeding with this service check, make sure you have the correct system board installed in the printer. The system board has a label with an board ID and barcode. Use the first eight numbers to identify the board with the part number in the table below:

Model 500S (003, 004, 005, 006) 500S (001, 002, 011, 012, 101, 102, 111, 112)

Board bar code M010 6030 M010 6000

Corresponds to P/N 40X3310 40X2722

This error code indicates a mismatch between the system board and the interface card. FRU 1 Interface card assembly Action If the interface card assembly has been recently replaced, go to step 3. If the interface card assembly has not been recently replaced, contact the next level of support. If the system board has been recently replaced, go to step 4. If the system board has not been replaced, contact the next level of support. Replace the current interface card assembly with the original interface card assembly. See Interface card assembly removal on page 4-107. If the error remains, go to step 5. Replace the current system board with the original system board. See System board and inner shield removal model500S" on page 4-131. If the error remains, go to step 6. Replace the original interface card assembly with a new and not previously installed interface card assembly. If the problem remains, contact the next level of support.

System board

Interface card assembly

System board

Interface card assembly

Diagnostic information

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FRU

Action Replace the original system board with a new and not previously installed system board. If the problem remains, contact the next level of support.

System board

ADF paper length sensor service checkmodel 500S

Note: There are two cables between the motor driver card and the paper length sensor. Check to make sure both cables are installed correctly. FRU 1 ADF paper length sensor (in ADF paper tray) Action Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the ADF paper length sensor for correct operation by putting a sheet of paper in the tray over the sensor. If the sensor does not operate properly, go to step 2. Turn the power off, and disconnect the cable to CN8, and measure the voltages at CN8 on the card. Measure the voltages shown in the table below:
Paper length sensorreflective type (normally closed) Connector CN8 (motor driver card) CN8Pin 4 CN8Pin 5 CN8Pin 6 0 V dc +5 V dc +5 V dc

ADF paper length sensor Motor control card

Note: All voltages are approximate values.

If incorrect, replace the motor driver card. If correct, go to step 3.

ADF paper length sensor

Turn the power off and reconnect CN8 to the motor driver card. Measure the voltages in the table below:
Interval sensorreflective type (normally closed) Connector CN8 (motor driver card) Pin number CN8Pin 4 CN8Pin 5 CN8Pin 6 Sensor closed 0 V dc +0.03 V dc +5.0 V dc Sensor open 0 V dc +5.0 V dc +5.0 V dc

Note: All voltages are approximate values.

If the voltages are incorrect, replace the paper length sensor. If this does not fix the problem, replace the ADF paper tray assembly. If the problem persists, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4.

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ADF paper width sensor service checkmodel 500S

Note: There are two cables between the motor driver card and the paper width sensor. Check to make sure both cables are installed correctly. FRU 1 ADF paper tray Action Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check the ADF paper width sensor for correct operation by moving the paper width guides on the paper tray in and out. If only one or two of the sensor widths does not operate properly, replace the ADF paper tray assembly. If none of the sensors operate correctly, replace the ADF paper tray. If this does not fix the problem, replace the motor driver card.

Charge roll service check

Service tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 in.) apart, or spots on the page can be caused by a damaged or contaminated dual charge roll. Service tip: Make sure the right charge roll arm bushing is correctly installed and operates correctly. To remove the charge roll:

1. Wrap a piece of plain white paper around the charge roll to prevent contamination or damage. 2. Carefully remove the roll by pressing outward and to the right on the charge roll link arm, and remove the
charge roll from the right side charge roll bearing.

3. Remove the charge roll from the left side charge roll bearing, and remove the roll from the printer. Leave
the paper wrapped around the charge roll until it is reinstalled. FRU 1 Charge roll assembly Action Check the charge roll for correct installation, toner buildup, marks, cuts, or other signs of contamination or damage. Replace as necessary. Check the left side charge roll link assembly for correct assembly operation. Check for damage to the arm or bearing assembly. Check the right side charge roll link assembly for correct assembly operation. If incorrect, replace the charge roll link assembly with the charge roll link assembly kit. If correct, check the right charge roll link assembly bearing for signs of wear or contamination. Excessive contamination could cause intermittent charging of the charge roll. If incorrect, replace the link assembly. Check for continuity of the right link assembly from the bearing to the charge roll high voltage contact on the right side frame. If incorrect, replace the link assembly. Make sure the charge roll bushing is installed and operating correctly. Note: The screw that attaches the charge roll lead to the contact must be secure.

2 3

Left side charge roll link Right side charge roll link Right charge roll bushing

Diagnostic information

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Cover closed sensors service checkflatbed

Note: Check for correct installation of the sensor cable before proceeding with this service check. Note: Both the cover closing sensor (A) and the cover closed (B) sensor are located in the ADF assembly.

A
FRU 1 Flatbed cover closing and flatbed cover closed sensors Flatbed closed and flatbed closing actuators Flatbed cover closed and closing sensors Action

Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check for correct operation of the senors by opening and closing the ADF scanner assembly. If incorrect, go to step 2. Check the flatbed actuators for any signs of a broken, damaged, or missing part. Replace either actuator if damaged or missing. Turn the power off, disconnect the cable to CN7, and measure the voltages at CN7 on the card. The voltages should measure as shown in the table below:
Paper length sensorreflective type (normally closed) Connector CN7 (motor driver card) CN7Pin 1 CN7Pin 2 CN7Pin 3 CN7Pin 4 CN7Pin 5 CN7Pin 6 0 V dc +5 V dc +5 V dc 0 V dc +5 V dc +5 V dc

2 3

Note: All voltages are approximate values.

If any of the voltages are incorrect, replace the motor driver card. If the voltages are correct, go to step 4.

Flatbed cover closing/ closed sensors cable

Check continuity of the flatbed cover closing/closed sensor cable. If incorrect, replace the complete ADF assembly. ADF complete assembly removal on page 4-15. Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See Scanner registration on page 4-4. If correct, replace the failing sensor.

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Cover closed switch/cable service checkprinter

FRU 1 Toner cartridge Action Make sure the toner cartridge is correctly installed and that the right and left cartridge tracks are not loose or broken. Make sure the cover closed switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover closed switch spring. Check the cover closed switch for proper mechanical operation. If incorrect, repair as necessary. Disconnect the cover closed switch cable from J8 at the system board and measure the voltage at J8-3. It measures approximately +5 V dc. If the voltage is incorrect, replace the system board. If the voltage is correct, check the voltage at J8-1. If the voltage measures greater than +1.0 V dc, replace the system board. If the voltage is correct, check the continuity between J8-1 and J8-3 on the cable. If no change in continuity occurs as the switch is activated, replace the hinge assembly. If the continuity changes as the switch is activated, replace the system board.

Cover closed switch/cable assembly

Cover closed switch table

J8 Pin number Pin 1-3 Pin 1-2 Cover open Open Closed Switch status Cover closed Closed Open

Dead machine service check

A dead machine is a condition where the LCD touchscreen is blank, the LED on the operator panel right cover is off, no fans turn, no motors turn, and the fuser lamp does not come on. If a high-capacity input tray is installed, remove the option and check the printer for correct operation. If the printer operates correctly, go to High-capacity feeder input tray service check on page 2-141. If the printer continues to not operate correctly, remove any other attached paper handling options. Warning: Observe all necessary ESD precautions when removing and handling the system board or any installed option cards or assemblies. See Handling ESD-sensitive parts on page 4-1. CAUTION When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task. Remove any input and output paper handling options from the printer. FRU 1 Line voltage AC line cord Action Check the AC line voltage. If the line voltage is incorrect, inform the customer. Unplug the line cord from the wall outlet and check the line cord for damage, such as, a damaged plug, or cut or damaged cord. If incorrect, replace the cord. If incorrect, check the continuity of the line cord and replace if necessary. If the cord is correct, go to step 3.

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FRU

Action Check for approximately +5 V dc at the +5 V test point on the system board. Note: Use care not to short adjacent voltage test points.

+5 V dc test point on the system board

If the voltage is correct, Go to step 9. If the voltage is incorrect, go to step 4.

System board

Check to make sure the LVPS cable is correctly installed at J27 on the system board. If not, reseat and recheck the voltage at the +5 V dc test point on the system board. If test point does not measure +5 V dc, go to step 5. Unplug the AC line cord from the LVPS and disconnect the LVPS cable to the system board. Reconnect the AC line cord and measure the voltage on CN2-1 on the LVPS. The voltage should measure approximately +5 V dc.

LVPS

If the voltage is correct, go to step 6. If the voltage is incorrect, replace the LVPS assembly. See Low voltage power supply removal on page 4-109

Features or option installed on the interface card assembly

Warning: Observe all the ESD precautions and turn the printer off before any feature or option cards are removed or replaced. Remove one option/feature at a time to help isolate the failing part. Replace the faulty part. Unplug the AC line cord, remove the LVPS from the printer, and check the continuity of fuse F1. See Low voltage power supply removal on page 4-109. If continuity is correct, replace the LVPS assembly.

LVPS fuse F1 (primary power)

Loads connected to the system board

Turn the printer off and disconnect each cable connected to the system board and each option installed on the system board until the problem is located. Warning: When removing any card installed on the system board observe all ESD precautions when handling these options. Check for the correct installation of the interface card to the printer system board and to the scanner control card. If correct, go to step 10.

Interface card Scanner control card

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FRU

Action Replace the following FRUs in the order shown one at a time in until the problem is fixed: Scanner control card. See Scanner control card removal on page 4-48. System board. See System board and inner shield removal model 500S on page 4-131. Interface card. See Interface card assembly removal on page 4-107.

10

System board Scanner control card Interface card

Duplex option service check

Duplex paper jams
23x.xx jam code 231.xx 232.xx 233.xx 234.xx 235.xx 236.xx 237.xx 238.xx r Jam location Media did not arrive at the duplex input sensor, but did leave the fuser exit sensor. Media did not clear the duplex input sensor, but did leave the printer fuser exit sensor. Media failed to make the duplex double feed sensor during turnaround. Media did not arrive at the duplex exit sensor. A piece of media is over the duplex double feed sensor. Media did not leave the duplex exit sensor. A duplexed sheet did not reach the printer input sensor. A piece of media is over the duplex sensors during a reset.

Duplex does not recognize that the option is installed, or other options below the duplex are installed
FRU 1 Autoconnect cables/ connections Action Check the top and bottom autoconnect connectors for signs of damage. If damaged, replace the duplex option. If not damaged, check the cables are correctly connected to the duplex system board at J9, J10, J11, and J12. If no problem is found, replace the duplex option.

Note: Before proceeding with the following service checks, verify the media used in the duplex option meets specification and is not dog-eared or damaged in any way. See Media specifications on page 1-9.

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231.xx Jam FRU 1

displays
Action Check the sheet of media is leaving the exit sensor in the fuser and feeding properly into the duplex option. Check the duplex link for correct operation and any signs of damage. If the problem is prior to the duplex input sensor and in the base machine, repair as necessary. If the jam occurs in the duplex option prior to the duplex input sensor, go to step 2. If the paper does not reach the duplex input sensor, make sure the sensor is connected to the duplex system board. If correct, check for any paper or other objects that might cause a paper jam. If none are found, replace the duplex option assembly.

Fuser exit sensor

Duplex input sensor

232.xx Jam FRU 1

displays
Action If the paper reaches the duplex input sensor, but does not clear the sensor, make sure the sensor is connected to the duplex system board. If connected correctly, check for correct operation of the sensor. If a problem is found and cannot be corrected, replace the duplex option assembly. If no problem is found, check for a piece of paper or other object in the paper path that might cause a paper jam over the input sensor. If no problem is found, replace the duplex option assembly.

Duplex input sensor

233.xx Jam FRU 1

displays
Action If a sheet of paper fails to reach the double feed sensor during turnaround, check for any signs of paper or other objects that might cause the paper to jam. If no problem is found, replace the duplex option assembly.

Duplex double feed sensor

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Envelope feeder service check

Service tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If any other options are installed make sure they are operating normally. If only the envelope feeder is failing to operate correctly, continue with this service check, otherwise verify the interconnect card is functioning properly. Service tip: The envelope feeder receives its +5 V dc operating voltage from the +24 V dc bulk at J1-7. If +24 V dc is not present at J1-7, tray 1 is the only tray that is recognized.

Printer does not recognize the envelope feeder as an attached input option
FRU 1 Envelope feeder Front autoconnect on printer Action Make sure the envelope feeder is correctly installed and mated to the autoconnect at the front of the printer. Check the connector for signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Remove the envelope feeder and check the voltages at the autoconnect on the front of the printer. If incorrect, check the system board. If correct, reinstall the envelope feeder and continue with step 3. Check for damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages: J1-3 measures +5 V dc J1-5 measures +5 V dc J1-7 measures +24 V dc If any of the voltages are incorrect, replace the autoconnect cable/ connector. If the voltages are correct, replace the envelope system board.

Autoconnect on the envelope feeder

Touchscreen displays 260.xx Paper Jam immediately when envelope feed is requestedPOST incomplete
FRU 1 Pass thru sensor Action Check for any debris or pieces of envelope over the pass thru sensor. Check for correct installation of the pass thru sensor flag. Make sure the sensor cable is attached to the envelope system board. Perform an envelope feeder sensor test to check both the sensor and sensor flag. Note: It may be necessary to use a small tool to actuate the sensor flag because it is located under the front cover. Be careful not to damage the flag. If the test fails, check the flag for damage or binds. If incorrect, replace the flag. If the flag is operating correctly, check the voltage at J3-3. The voltage measures approximately +5 V dc. If incorrect, replace the envelope system board. If correct, check the voltage at J3-2. The voltage changes from 0 to +5 V dc when the flag is moved in and out of the sensor. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the envelope system board.

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Touchscreen displays 260.xx Paper Jam after attempted feed but before envelopes are put in the hopper OR the touchscreen continues to display Load Envelopes after envelopes are placed in the hopper
Service tip: The kick rolls rotate during the attempted feed cycles. FRU 1 Envelope out hopper sensor flag Action Check the envelope out sensor flag for damage, correct installation and operation. If incorrect, repair or replace the envelope feeder option.

990.xx Service Error, envelopes fail to feed from the hopper

FRU 1 DC feed motor assembly Action Check the motor and motor cable for loose wires or poor connections. Make sure the motor cable is connected to the envelope system board. If correct, replace the envelope feeder option.

260.xx Paper Jam displays, unable to clear and envelopes fail to feed from the hopperKick rolls are not rotating FRU 1 Clutch latch assembly Action Check the clutch latch assembly to make sure it moves freely. If correct, replace the envelope feeder option.

260.xx Paper Jam displays, unable to clear and envelopes fail to feed from the hopper Kick rolls are rotating. Check the deflector gap adjustment before continuing this service check. FRU 1 Deflector gap adjustment Weight assembly Action Check the deflector gap adjustment. The adjustment may be too narrow. Check the weight assembly to make sure it moves up and down freely without any binds. Make sure the weight assembly rests on all the rear kick rollers when the hopper is empty. If the weight assembly is damaged or does not operate properly, replace the envelope feeder assembly. Check the envelope edge guide to make sure it is not warped or set too close to the envelopes in the hopper. If the edge guide is damaged or does not operate properly, replace the envelope feeder option.

Envelope edge guide

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260.xx Paper Jam displays, envelope stops in feeder paper path

FRU 1 Kick rolls/feed rolls/drive rolls Deflector gap adjustment Action Check all the rolls for oil, grease, or other contamination. If you find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder. Check the deflector gap adjustment. The adjustment may be too narrow. If the adjustment is correct, replace the envelope feeder option.

Envelope feeder multifeeds or may not display a 260.xx Paper Jam message
FRU 1 Envelopes Action Check the envelopes being used in the feeder. Check for signs of the envelopes being stuck together or signs of glue. Make sure the flaps are not interleaved. If the envelopes meet the guidelines and are properly loaded, go to step 2. Check the deflector gap adjustment. The adjustment may be too wide. If the deflector gap adjustment is correct, go to step 3. If not, replace the envelope feeder option. Check for a missing, broken or incorrectly installed restraint roll bias spring. If incorrect, replace the envelope feeder option.

Deflector

Restraint roll bias spring

260.xx Paper Jam displays, an envelope stopped in the paper path of the feeder and an envelope also stopped in the printer paper path
FRU 1 Latch lever Action Make sure the tip of the latch lever is centered in the opening in the floor of the paper path. The latch lever may not be detented on the latch. If no problem is found and the problem persists, replace the envelope feeder option.

Flatbed size sensor service check

Check for correct installation of the sensor cable before proceeding with this service check. Note: All three sensors and their cables come attached together as a unit. FRU 1 Flatbed paper size sensor assembly Flatbed interface card assembly Action Enter the Diagnostics Menu (turn on MFP while holding 3 and 6), select SCANNER TESTS, and select Sensor Tests. Check for correct operation of the sensors by placing a piece of paper on the contact glass over the sensor assembly. If any sensor fails the sensor test, replace the sensor assembly. If this does not fix the problem, replace the flatbed interface card. See Flatbed interconnect card removal on page 4-33.

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Fuser service checks

920.xxCold fuser service check
Error codes 920.x and 922.xx may display for a cold fuser failure. Some 920.xx error codes may be cleared by turning the printer on and off and allowing it to complete POR. CAUTION 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. Service tip: Some 920.xx errors can be caused by multiple sheets of paper being fed up to the fuser. Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, select EP SETUP, and Fuser Temp. Service tip: It may take several minutes for the error codes 920.xx and 922.xx to be displayed after the printer is turned on. FRU 1 Fuser lamp Fuser lamp AC cable Action Observe the lamp through the left near side of the printer. It may be necessary to remove the redrive assembly to observe the lamp turning on and off. If the lamp does not come on do the following: If not previously removed, remove the redrive assembly. See Redrive assembly removal on page 4-128. Remove the fuser assembly. See Fuser assembly removal on page 4-79. Make sure the correct type of lamp is installed (voltage and wattage). Verify that the fuser to fuser lamp cable is installed correctly to the fuser top cover assembly. If incorrect, install correctly; if correct, go to step 2. CAUTION: When taking measurements for AC power, observe all safety precautions. Check the AC line voltage to make sure it is within operating specification. If incorrect, inform the customer; if correct, go to step 3. CAUTION: When taking measurements for AC power, observe all safety precautions. Unplug the AC line cord from the printer and pull the LVPS out far enough to access CN1 on the LVPS board (see Low voltage power supply removal on page 4-109). Disconnect the LVPS to fuser AC cable, plug in the line cord, turn the printer on and measure the voltage between CN1-1 and CN1-3 on the connector (see the connector locations at Low voltage power supply on page 5-11). If incorrect, replace the LVPS assembly (see Low voltage power supply removal on page 4-109); if correct, go to step 4.

AC line voltage

LVPS

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FRU

Action Check continuity of the fuser to fuser AC cable, fuser top cover assembly, and fuser lamp by checking the continuity between the two pins on the fuser lamp AC cable connector: If there is continuity, go to step 5. If there is no continuity, check the continuity of the fuser to fuser lamp AC cable. If incorrect, replace the lamp, if incorrect, replace the fuser top cover assembly. Note: If the fuser lamp is replaced, allow the fuser assembly to cool or a 925.xx error may be displayed. CAUTION: When taking measurements for AC power, observe all safety precautions. Check the AC line voltage between the pins on the fuser end of the LPVS to fuser AC cable. If the voltage is correct, unplug the AC power cord from the LVPS cable. If the voltage is correct, unplug the AC power cord from the LVPS, pull the LVPS out far enough to be able to check the voltage between CN-1 and CN1-3 on the LVPS board. Plug in the power cord, turn the printer on and check the voltage. If correct, replace the LVPS to fuser AC cable; if incorrect, replace the LVPS assembly. Note: If the fuses in the LVPS are blown, the LVPS assembly must be replaced. Check to make sure that the thermistor is installed correctly to J5 on the fuser control card. If installed correctly check the cable for any signs of damage. If any problems are found, replace the fuser top cover assembly. If no problem is found, check the fuser to system board DC cable for correct installation at J1 on the fuser control card. If no problem is found, check the fuser to system board cable for correct installation at J10 on the system board. Carefully check the installation of the LVPS to system board cable to J27 on the system board and to CN2 on the LVPS. If the cable is not seated or installed properly, reseat the cable and retry the printer. If the cable is installed correctly, replace the following FRUs in the order shown: LVPS assembly. See Low voltage power supply removal on page 4-109. System board assembly. See System board and inner shield removal model 500S on page 4-131. LVPS to system board cable. If no problem is found up to this point, then replace the following in the order shown: Fuser assembly. See Fuser assembly removal on page 4-79. System board assembly. See System board and inner shield removal model 500S on page 4-131. LVPS. See Low voltage power supply removal on page 4-109.

Fuser lamp Fuser top cover assembly Fuser connect cable (fuser to fuser lamp cable)

LVPS LVPS to fuser AC cable

Fuser top cover assembly (thermistor, thermistor cable) Fuser to system board DC cable

Error code 920.06 displayed LVPS System board System board to LVPS cable

Fuser assembly

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922.xxCold fuser check

Error codes 920.xx and 922.xx may display for a cold fuser failure. Some 920.xx error codes may be cleared by turning the printer on and off and allowing it to complete POR. CAUTION 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. Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, select EP SETUP, and Fuser Temp. FRU 1 Fuser lamp Action Remove the fuser assembly and check to make sure the correct fuser lamp has been installed. If the correct lamp has been installed, go to step 2. Note: If the fuser lamp is replaced, allow the fuser assembly to cool or a 925.xx error code could be displayed. CAUTION: When taking measurements for AC power, observe all safety precautions. Check the AC line voltage to make sure it is within operating specification. If incorrect, inform the customer; if correct, go to step 3. CAUTION: When taking measurements for AC power, observe all safety precautions. Unplug the AC line cord from the printer and pull the LVPS out far enough to access CN1 on the LVPS board (see Low voltage power supply removal on page 4-109). Disconnect the LVPS to fuser AC cable, plug in the line cord, turn the printer on and measure the voltage between CN1-1 and CN1-3 on the connector (see the connector locations at Low voltage power supply on page 5-11). If incorrect, replace the LVPS assembly (see Low voltage power supply removal on page 4-109); if correct, go to step 4. CAUTION: When taking measurements for AC power, observe all safety precautions. Disconnect the AC line cord from the printer. Disconnect the LVPS to fuser cable from the fuser to fuser lamp cable. Plug the AC line cord into the printer and check the AC line voltage between the pins on the fuser end of the LVPS to fuser AC cable. If the voltage is correct, unplug the AC power cord from the LVPS cable and pull the LVPS out far enough to be able to check the voltage between CN-1 and CN-3 on the LVPS board. Plug in the power cord, turn the printer on and check the voltage. If correct, replace the LVPS to fuser AC cable; if incorrect, replace the LVPS assembly. See Low voltage power supply removal on page 4-109. Note: If the fuses in the LVPS are blown, the LVPS assembly must be replaced.

AC line voltage

LVPS

LVPS LVPS fuser AC cable

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FRU

Action Check to make sure that the thermistor is installed correctly to J5 on the fuser control card. If installed correctly check the cable for any signs of damage. If any problems are found, replace the fuser top cover assembly.Fuser narrow media sensor removal on page 4-88. If no problem is found, check the fuser to system board DC cable for correct installation at J1 on the fuser control card. If no problem is found, check the fuser to system board cable for correct installation at J10 on the system board. If no problem is found, go to step 6. If no problem is found up to this point, then replace the following in the order shown: Fuser assembly. See Fuser assembly removal on page 4-79. System board assembly. See System board and inner shield removal model 500S on page 4-131. LVPS. See Low voltage power supply removal on page 4-109.

Fuser top cover assembly (thermistor, thermistor cable) Fuser to system board DC cable

Fuser assembly

923.xxHot fuser service check

Error Code 923.xx, 924.xx, and 925.xx may display for a hot fuser failure. CAUTION The fuser may be hot, use caution before removing or servicing.

CAUTION 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. Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, In Diagnostics mode, select EP SETUP, and Fuser Temp. FRU 1 Fuser assembly Action Check for any signs of overheating in the fuser assembly. Check the hot roll, hot roll bearings, and the area around the thermistor for any signs of excessive heat. If a problem is found, replace the thermistor. If no problem is found, go to step 2. Turn the printer off and disconnect the fuser to system board cable from J10 on the system board. Check the resistance between pins J10-3 and J10-4. The resistance should be greater than 100K ohms. If correct, go to step 3; if incorrect, disconnect the thermistor cable from J5 on the fuser board and measure the resistance between the two pins on the thermistor cable. If incorrect, replace the fuser top cover assembly (see Fuser narrow media sensor removal on page 4-88); if correct, replace the fuser to system board cable. Check the voltage on J10-3 ground on the system board. The voltage should measure approximately +3.3 V dc. If the voltage is correct, replace the fuser top cover assembly. See Fuser narrow media sensor removal on page 4-88. If incorrect, replace the system board. See System board and inner shield removal model 500S" on page 4-131.

Fuser top cover assembly (thermistor)

System board Fuser top cover assembly

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924.xxHot fuser service check

Error Code 923.xx, 924.xx, and 925.xx may display for a hot fuser failure. CAUTION The fuser may be hot, use caution before removing or servicing.

CAUTION 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. Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, In Diagnostics mode, select EP SETUP, and Fuser Temp. FRU 1 Fuser assembly Fuser to system board cable Fuser top cover assembly (thermistor/thermistor cable assembly) Fuser to system board cable. System board Fuser assembly Action Check the thermistor cable for correct installation to J5 on the fuser card. If installed correctly, check for correct installation of J10 on the system board. If all cables are installed correctly, go to step 2. Turn the printer off and disconnect the thermistor cable from J5 on the fuser board. Measure the resistance between the two pins on the thermistor cable, if the resistance measures infinity (open circuit), replace the fuser top cover assembly. Reconnect the thermistor cable to J5 on the fuser board. Disconnect the fuser to system board cable from J10 on the system board and measure the resistance between J10-3 and J10-4 on the cable. If the resistance measures infinity (open circuit) check the continuity of pins 3 and 4 of the cable. If correct, replace the fuser assembly. See Fuser assembly removal on page 4-79. If incorrect, replace the fuser to system board cable. Note: If the error code still displays, replace the system board. See System board and inner shield removal model 500S" on page 4-131.

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925.xxHot fuser service check

Error Code 923.xx, 924.xx, and 925.xx may display for a hot fuser failure. CAUTION The fuser may be hot, use caution before removing or servicing.

CAUTION 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. Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, In Diagnostics mode, select EP SETUP, and Fuser Temp. FRU 1 Fuser lamp Action If the fuser is 220 V machine a 115 V fuser may be installed. If the printer is not a 115 V model, then go to step 2. If the printer is a 220 V model, then check to make sure that the correct lamp is installed. Note: If the fuser lamp is replaced, allow the fuser to cool or a 925.xx error could be displayed. Check the AC power source to make sure it meets specifications. If the AC power source does not meet specifications, inform the customer. If it meets specifications, go to step 3.

AC power source

Fuser lamp

Turn the printer off and allow the fuser assembly to cool. After the fuser assembly cools down, turn the printer on. If you receive the same error code, replace the fuser lamp. See Fuser lamp removal on page 4-86. Note: If the fuser lamp is replaced, allow the fuser to cool or a 925.xx error could be displayed.

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Fuser exit sensor service check

If any of the following codes are displayed, there is a potential problem in the area of the exit sensor: 201.00, 201.02, 201.10, 201.12, 201.22, 201.30, 201.32, 201.40, 201.41, 201.42, 201.50, 201.52, 201.92, 202.00, 202.02, 202.04, 202.10, 202.11, 202.12, 202.14, 202.20, 202.21, 202,22, 202.24. 202.30, 202.31, 202.32, 202.34, 202.40, 202.41, 202.42, 202.44, 202,50, 202.51, 202.52, 202.54, 202.90, 202.91, 202.92, and 202.94.

Fuser exit and fuser narrow media sensor status chart

Printer not printing no media over sensors Exit sensor open Narrow media sensor open Printer printingmedia over sensor(s), non-narrow media fed through the printer Exit sensor closed Narrow media sensor closed Printer printingnarrow media fed through the printer Exit sensor closed Narrow media sensor open

FRU 1 Fuser exit sensor (exit sensor test) Fuser exit sensor cable

Action Enter the Diagnostic mode, select BASE SENSOR TEST, select the Exit Sensor to test for proper operation. If the exit sensor fails the test, go to step 2. If the exit sensor passes, go to step 5. Check the fuser exit sensor cable for correct installation or for any signs of damage to the cable or connectors. If no problem is found, go to step 3. If a problem with the installation is found, install the cable correctly. If damage to the cable or connectors is found, replace the cable. Make sure the sensor flag is not binding and is operating properly. If the sensor is operating properly, go to step 4. If it is not operating properly, repair or replace the sensor assembly. See Fuser exit sensor removal on page 4-82. Check the continuity of the fuser exit sensor cable. If incorrect, replace the cable; if correct check the continuity of the fuser to system board cable. If incorrect, replace the cable; in correct, replace the following FRUs in the order shown: Fuser board. Fuser assembly. See Fuser assembly removal on page 4-79. System board. See System board and inner shield removal model 500S" on page 4-131. With the redrive assembly removed from the printer, enter the Diagnostics mode and run the print test from tray 1 (for example, select PRINT TESTS, Tray 1, and Continuous) and observe the media as it passes over the exit and narrow media sensors. Check that the sensor flags are operating correctly. If the sensor flags and hardware are operating incorrectly, repair or replace the failing sensor assembly. If no problem is found, check the fuser for any signs of media in the fuser or any signs of toner or other contamination. If a problem is found, clean or remove the debris or contamination.

Fuser exit sensor flag

Fuser assembly Fuser exit sensor cable Fuser board Fuser to system board cable System board

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Fuser narrow media sensor service check

If any of the following error codes are displayed, a problem may exist in the area of the narrow media sensor assembly: 201.04, 201.14, 201.24, 201.34, 201.44, 201.54, and 201.94.

Fuser exit and fuser narrow media sensor status check

Printer not printing no media over sensors Exit sensor open Narrow media sensor open Printer printingmedia over sensor(s), non-narrow media fed through the printer Exit sensor closed Narrow media sensor closed Printer printingnarrow media fed through the printer Exit sensor closed Narrow media sensor open

FRU 1 Fuser narrow media sensor (sensor test)

Action Enter the Diagnostics mode, select BASE SENSOR TEST, and select the NM Sensor to test it for proper operation. If the narrow media sensor fails the test, go to step 2; if the narrow media sensor does not pass the test, go to step 5. Check the fuser narrow media sensor cable for correct installation or any signs of damage to the cable or to the connectors. If no problem is found, go to step 3;. If a problem with the installation is found, install the cable correctly. If damage to the cable or the connectors is found, replace the cable. Make sure the sensor flag is not binding and is operating properly. If the sensor is operating properly, go to step 4. If the sensor is not operation properly, repair or replace the sensor assembly. See Fuser narrow media sensor removal on page 4-88. Check the continuity of the fuser narrow media sensor cable. If incorrect, replace the cable; if correct, check the continuity of the fuser to system board cable. If incorrect, replace the cable; if correct, replace the following FRUs in the order shown: Fuser board Fuser assembly. See Fuser assembly removal on page 4-79. System board. See System board and inner shield removal model 500S on page 4-131. With the redrive assembly removed from the printer, enter Diagnostics mode and run the printer test from tray 1 and observe the media as it passes over the exit sensor. Check to see that the sensor flag is operating correctly. If the sensor flag and hardware are operating incorrectly, repair or replace the failing sensor assembly. If no problem is found, check the fuser for any signs of media in the fuser or any signs of toner or other contamination. If a problem is found, clean or remove the debris or contamination.

Fuser narrow media sensor cable

Fuser narrow media sensor flag

Fuser assembly Fuser narrow media sensor cable Fuser board Fuser to system board cable System board

Diagnostic information

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Fuser solenoid service check

CAUTION 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. Service tip: Try changing the envelope enhance level setting. A different setting may correct the problem. Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section Fuser solenoid adjustment on page 4-2. FRU 1 Fuser envelope conditioner solenoid Action Observe the operation of the fuser solenoid by removing the redrive assembly. Check for proper mechanical operation of the solenoid and associated hardware, link, and so on. If correct, check the resistance of the solenoid between J4-1 and J4-2 on the fuser control board.

The resistance measures between 5 ohms and 10 ohms. If incorrect, replace the fuser assembly. If correct, go to step 2.

System board

Measure the voltage at the +50 V dc test point on the system board. The voltage should measure approximately +50 V dc. If incorrect, go to step 3. If incorrect, go to step 4. Measure the voltage at CN2-18 on the LVPS. The voltage should measure approximately +50 V dc. If incorrect, replace the LVPS assembly. See Low voltage power supply removal on page 4-109. If correct, replace the system board. See System board and inner shield removalmodel 450S on page 4-130 or System board and inner shield removal model 500S" on page 4-131. Make sure the cable is connected properly to the system board and fuser control board. Reconnect the cable, if necessary. If the cable is connected correctly, go to step 5. If no problems were found in steps 1 through 4, replace the fuser assembly. See Fuser assembly removal on page 4-79.

LVPS

Fuser board to system board cable Fuser assembly

2-140 Service Manual

High-capacity feeder input tray service check

Note: Voltage measurements in the high-capacity feeder input tray service checks must be made with the highcapacity feeder attached to the printer to obtain accurate results. Service tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high-capacity feeder tray. Service tip: Check the other paper sources to be sure they are operating correctly.

The printer indicates a dead machine condition when the high-capacity input tray is installed
FRU 1 AC line cord AC jumper (HCIT to printer) AC input and output receptacles AC wiring harness Action If the printer works normally using the AC line cord from the AC wall outlet and does not work when using the AC jumper from the HCIT, check the AC jumper cord. If defective, replace the cord. If not defective, check the AC input and output receptacles and wiring harness in the HCIT. Repair or replace the receptacles or AC wiring harness as required. Note: Make sure the ground wire is installed correctly from the AC wiring harness to the frame of the HCIT and the nut and lock washer are tightened.

The MFP does not recognize that the high-capacity input tray is installed
FRU 1 high-capacity feeder autoconnect mechanical check Action Check the high-capacity feeder input tray to make sure it is mounted correctly and is not pushed down into the frame assembly or damaged. Be sure the high-capacity feeder input tray autoconnect is properly connected to the high-capacity feeder tray option board assembly. Check the option or printer autoconnect for signs of damage. Repair the high-capacity option autoconnect as necessary. Check the voltages at J11-2 and J11-4. The voltage measures +24 V dc, If the voltage is correct, replace the high-capacity system board assembly. If the voltage is incorrect, check the continuity of the AC input cable to the LVPS. If correct, replace the LVPS assembly. If incorrect, replace the AC cable to the input of the LVPS.

2 3

Printer or option mounted above LVPS Option system board

Diagnostic information

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FRU

Action Check the voltage on J8-1 (green). The voltage measures +24 V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the printer through the autoconnect system to the high-capacity input for the high-capacity feeder to be recognized. If the voltage is correct, check the voltages at J11-3(red) and J11-4(red). The voltages measure +24 V dc. If correct, replace the high-capacity feeder option system board. If incorrect, disconnect J8 from the system board and measure the voltages again. If incorrect, check the LVPS cable and the AC internal wiring from the input appliance receptacle. If incorrect, replace as necessary. If correct, replace the LVPS. If the voltages are correct, check the stepper motor for shorts from the motor housing to each pin on the motor connector. If you find a short between any pin and the motor housing, replace the motor assembly. If no shorts are found, replace the high-capacity feeder option control board. Check the voltage at J9-1 (light blue). The voltage measures approximately +24 V dc. If incorrect, disconnect the cable at J9 and check the voltage again. If the voltage continues to be incorrect, replace the high-capacity feeder option system board. If the voltage measures correctly, check the cable. If the cable is damaged, replace as necessary. If no problem is found with the cable, replace the highcapacity feeder option control board.

High-capacity feeder option control board

24x.xx Paper Jam

displays, paper jammed over the pass thru sensor

Where x=the printer displays the value of x for the paper tray where the error occurs. For example: 242.xx is a Paper Jam Tray 2 FRU 1 Pass thru sensor and flag assembly Action The tray x option system board did not detect a piece of paper actuating the pass thru sensor. Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu. If the test fails, check the sensor for correct installation and the flag for proper operation. Also check the sensor cable to make sure it is correctly connected to the option system board. If incorrect, replace the tray x option pass thru sensor assembly. Check these parts for signs of broken or damaged parts, contamination on the drive rollers or wear plate and wear or damage to the drive shaft bearings. Check the drive roll assembly and skewed backup roller for wear, slick spots, material buildup, and oil or grease on the rollers. Also check for proper operation of the paper aligning assembly. Repair or replace parts as necessary.

Power takeoff shaft and spring, bevel gear, feed roll gear, drive roll assembly, wear plate, drive shaft bearings, and skewed backup roller

Tray x Paper Low FRU 1

displays when tray x is full or has adequate paper in the tray

Action Run the sensor diagnostics for tray x (x=the number that represents the high-capacity input tray). If the test fails, disconnect the paper low switch cable from J3 on the high-capacity system board. Short pins 1 and 2 together while observing the sensor test on the display. If the display does not change, replace the high-capacity feeder system board. If the display changes check the continuity of the switch. If incorrect, replace the switch. If correct, replace the switch cable.

Paper low switch Paper low switch cable High-capacity feeder Input system board

2-142 Service Manual

Tray x Empty FRU 1

displays when there is paper in the high-capacity feeder input tray

Action Check the paper out sensor flag for correct operation and installation. If correct, replace the high-capacity feeder system board. (The paper out sensor is mounted on the high-capacity feeder system board.)

Paper out sensor flag Paper out sensor (on option system board)

The elevator tray fails to stop at the correct position and continues to drive into the bottom frame
FRU 1 Lower limit switch Lower limit switch cable Action Check continuity of the lower limit switch. If incorrect, replace the switch. If correct, check the switch cable. If incorrect, replace the cable. If correct, replace the high-capacity feeder option control board. Disconnect the lower limit switch cable and check the voltage at J2-1 (orange). The voltage measures approximately +5 V dc. If incorrect, replace the high-capacity feeder option control board.

High-capacity feeder control board

The elevator tray down button does not operate. The tray moves to the upper position
Service tip: Open the high-capacity feeder front door and check the black rubber bumper attached to the door switch spring. Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly. FRU 1 Lower limit switch Lower limit switch cable High-capacity feeder control board Action Check the lower limit switch to make sure it is not closed (normally open). If incorrect, replace the switch. Check the lower limit switch cable for a short between pins 1 and 2. If incorrect, replace the cable. If correct, replace the high-capacity feeder control board.

Paper from the high-capacity feeder input tray does not reach the pass thru sensor
Service tip: Be sure the paper in tray is within specifications. FRU 1 Autocompensator assembly Wear strips Action Check the autocompensator pick arm rollers for sign of glazing, toner or other buildup. Replace as necessary. Check the wear strips for glazing or contamination. Replace as required. It is advisable to replace all four wear strips at the same time.

Diagnostic information

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The elevator tray does not move up or down; the printer recognizes that the option is installed
FRU 1 DC drive motor highcapacity feeder option system board Action Be sure the motor cable is correctly installed at J1 on the board. Check the cables, damaged or loose wires. Disconnect the motor. Check for a short between each pin and the motor housing. If a problem is found, replace the motor assembly. If no problem is found, measure the resistance between the following pins on the motor cable connector: Pins 1 (brown) and pin 2 (Yellow) The resistance measures between approximately 7.5 and 10.5 ohms. If incorrect, replace the motor assembly. If correct, replace the highcapacity feeder option system board.

The elevator moves in one direction only

FRU 1 DC drive motor assembly high-capacity feeder system board Action Check the voltages at J1 on the high-capacity system board. The voltages measure approximately as follows:
Pin J1-1 J1-2 J1-1 J1-2 J1-1 J1-2 Color Brown Yellow Brown Yellow Brown Yellow Voltage 0 V dc 0 V dc 0 V dc +24 V dc +24 V dc 0 V dc Static (motor not running)

Motor running forward

Motor running in reverse

If any of the voltages are incorrect, disconnect the motor and measure the resistance between J-1 and J-2. The resistance measures between 7.5 and 10.5 ohms. If incorrect, replace the motor. If correct, replace the system board.

2-144 Service Manual

Paper size switch not selecting paper size that is selected

FRU 1 Paper size switch High-capacity feeder option control board Action Check for continuity between the common pin (J5-1) and the pin of the paper size selected.
Pin J5-1 J5-2 J5-3 J5-4 J5-5 J5-6 J5-7 Color Black Blue Green Yellow Orange Red Brown Paper size Common lead B5 Executive A4 Letter Legal A5

If any position does not measure continuity when selected, replace the paper size switch assembly. If the switch assembly is operating correctly, replace the high-capacity feeder option control board. 24x.xx Paper Jam Check Tray x FRU 1 High-capacity feeder option control board

displays when tray x is empty; tray x does not display

Action Check the voltages on the board at J4-1(red) and J4-3 (blue). The voltages measure approximately +5 V dc. If incorrect, disconnect J4 from the board and measure the voltages again. If incorrect, replace the high-capacity feeder option control board. Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly.

Elevator top optical sensor cable Elevator top optical sensor

Tray x Empty displays; tray does not respond to loading paper; no response from the front door switch FRU 1 High-capacity feeder option control board Action Check the voltage on the board at J4-2 (green). The voltage measures approximately +5 V dc. If incorrect, disconnect the cable at J4 and check the voltage again. If incorrect, replace the high-capacity feeder option control board. Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly.

Elevator top optical sensor cable Elevator top optical sensor

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Tray x Paper Low

displays when the high-capacity feeder input tray is full or has adequate paper in the tray
FRU 1 Paper low switch Paper low switch cable High-capacity feeder option control board Action Run the sensor diagnostics for tray x (x=the number that represents the high-capacity input tray). If the test fails, check the voltage at J3-1 (gray). The voltage measures approximately +24 V dc. If incorrect, disconnect the paper low switch cable from J3 and measure the voltage again on J3-1. If incorrect, replace the high-capacity feeder option control board. If correct, check the cable for a short between pins 1 and 2 on the cable. If incorrect, replace the cable. If correct, check the switch for a bent or deformed actuator lever or defective switch. If incorrect, replace the switch.

Excessive noise or vibration

FRU 1 DC motor assembly Idler pulley DC motor assembly Drive pulley Motor drive belt tray drive belt Action Make sure all the motor plate mounting screws are tight. Make sure the idler pulley is not binding on the pulley shaft. Check the pulley for wear. Check the idler pulley shaft on the motor mounting plate for damage or contamination. Check the drive pulley for wear, binds or damage to the pulley or pulley shaft. Make sure the pulley turns freely on the pulley shaft. Check the DC motor drive belt for damage. Make sure the belt is tracking correctly on the drive pulley, idler pulley, and motor pulley. Check the tray drive belt for damage. Make sure the belt is tracking correctly on the lower section of the drive pulley and lead screw pulleys.

3 4

Input sensor service check

Service tip: Run the Base Sensor Test. Check the input sensor for proper operation. The display changes from open to closed as the sensor flag is manually moved in and out of the sensor. FRU 1 Input sensor flag System board Input sensor cable Action Check the input sensor flag for damage and proper operation. If a problem is found, repair as necessary. Check for approximately +5 V dc at J15-10 on the system board. If incorrect, replace the system board. Check the continuity of the input sensor cable section of the front wiring harness. If incorrect, replace the harness. If correct, replace the input sensor assembly.

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2-146 Service Manual

Input tray(s) service check

Optional 250-sheet and 500-sheet trays
Service tip: Try all the other input paper sources to make sure they are properly feeding paper. For 990 Error Code- Service Tray x, x= displays the number of the tray that has a problem or needs service. FRU 1 Tray x Option system board or compensator assembly or autoconnect cable Action Check the autoconnect cables and connectors for damage. If the cables, connectors, and connections are good, replace the FRUs in the following order: Autocompensator assembly option Replace the option.

24x.xx Paper Jam

displays, paper jammed over the pass thru sensor

(The printer displays the value of x for the paper tray where the error occurs. Example: 241 is a Paper Jam Tray 1) FRU 1 Pass thru sensor and flag assembly Action The tray x option system board did not detect a piece of paper actuating the pass thru sensor. Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu. If the test fails, check the sensor for correct installation and the flag for proper operation. Also check the sensor cable to make sure it is correctly connected to the option system board. If incorrect, replace the tray x option pass thru sensor assembly. Check these parts for broken or damaged parts, contamination on the drive rollers or wear plate, and wear or damage to the drive shaft bearings. Check the drive roll assembly and skewed backup roller for signs of wear, slick spots, material buildup, and oil or grease on the rollers. Also check for proper operation of the paper aligning assembly. Repair or replace parts as necessary.

Power takeoff shaft and spring, bevel gear, feed roll gear, drive roll assembly, wear plate, drive shaft bearings, and skewed backup roller

Tray x Low FRU 1

displays when tray x is full or has adequate paper in the tray

Action Run the Tray x Sensor Test and check the sensor for proper operation. If incorrect, check the following: Paper low sensor flag for smooth and correct operation. Paper low sensor for correct installation on the autocompensator housing. Paper low sensor cable for signs of cuts, pinched wiring, or other damage especially at connector J26 on the system board. If no problem is found, replace the paper low sensor assembly. If this does not correct the problem, replace the option system board.

Paper low sensor assembly Paper low sensor flag tray x option system board

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Tray x Empty FRU 1

displays when tray x has paper in the tray

Action Check the paper out sensor flag for correct operation and installation. If correct, replace the option system board. (The paper out sensor is mounted on the system board).

Paper out sensor flag Paper out sensor (on option system board)

Printer does not recognize Tray x is installed

FRU 1 Autoconnect cables Tray x system board Action Check the autoconnect from the printer or option above tray x. Check for cuts, pinched wiring, or damage to the contacts in the connector. Check the autoconnect cable(s) for correct installation at the tray x system board. If correct, replace the tray option.

Paper from Tray x does not reach the pass thru sensor
Service tip: Check the media in tray x to make sure it is within specifications. Some types of labels, foil material, and slick papers can cause misfeeds and slippage of the rollers. FRU 1 Autocompensator assembly Action Check the autocompensator pick arm rollers for any sign of glazing, toner or other buildup. Clean or replace as necessary.

Interface card service check

Warning: When replacing any one of the following components:

Flatbed interconnect card (ICC) System board assembly Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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.

Check the interface card for correct installation and for any signs of damage. If the card is damaged, replace the interface card. See Interface card assembly removal on page 4-107.

2-148 Service Manual

LCD touchscreen contrast control service checkmodel 500S

Note: If the contrast control only works over part of its travel, replace the left operator panel cover assembly. See Operator panel left cover assembly removal on page 4-61.

FRU 1 UICC card #1 to UICC card #3 cable (UICC 8-pin cable) UICC card #1 to UICC card #3 cable (UICC 8-pin cable) Operator panel left cover assembly

Action Check the cable for correct installation to J1 on UICC card #3 and to J14 on UICC card #1 (operator panel card). Check continuity of the UICC 8-pin cable. If correct, go to step 3. If incorrect, replace the cable. Replace the operator panel left cover assembly. See Operator panel left cover assembly removal on page 4-61. If this does not fix the problem, replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64.

LCD touchscreen display service checkmodel 500S

LCD touchscreen display complete dark operator panel LED on
CAUTION When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task. Note: The LCD touchscreen display can be checked by entering the Diagnostics Menu, selecting HARDWARE TESTS, and running the Panel Test. FRU 1 LCD inverter 8-pin cable Action Check the inverter 8-pin cable for correct installation to the operator panel card (J13) and to the LCD inverter card (CN1) assemblies. If no problem is found, go to step 2.

LCD inverter 8-pin cable

Check continuity of the inverter 8-pin cable. If incorrect, replace the cable. If correct, go to step 3.

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FRU

Action Check the voltages at CN1-1 and CN1-2.

LCD inverter card

LCD Touchscreen display Connector CN1 (LCD inverter card)

Operator panel right cover assembly LCD touchscreen display

Display dark CN11 Power CN12 Power CN13 Ground CN14 Ground CN15 Lamp Off CN16 Vbright adj CN17 Ground CN18 Ground +12 V dc +12 V dc 0 V dc 0 V dc 0 V dc 0 V dc 0 V dc 0 V dc

Display lit +12 V dc +12 V dc 0 V dc 0 V dc +4 V dc +4 V dc* 0 V dc 0 V dc

Note: All voltages are approximate values. *approximate, depending on brightness.

If the voltages at CN1-1 and CN-2 are incorrect, replace the LCD inverter card. See LCD inverter card assembly removal on page 4-108. If this does not fix the problem, replace the operator panel right side cover assembly. See Operator panel right cover assembly removal on page 4-64. If the voltages at CN1-1 and CN1-2 are correct, replace the inverter card. If this does not fix the problem replace the touchscreen display. See LCD touchscreen removal model 500S on page 4-67.

2-150 Service Manual

LCD touchscreen backlightmodel 500S

Unable to change LCD touchscreen backlight. FRU 1 Inverter card 8-pin cable Action Check to make sure the cable is installed correctly to the inverter card and to the operator panel card.

Inverter card 8-pin cable

Check continuity of the 8-pin inverter card cable. If correct, go to step 3. If incorrect, replace the cable.

Inverter card

Check the voltages on CN1-1 and CN1-2. They should measure approximately +12 V dc.
Inverter card Connector Cn1 (to operator panel card) Pin number CN1Pin 1 CN1Pin 2 CN1Pin 3 CN1Pin 4 CN1Pin 5 CN1Pin 6 CN1Pin 7 CN1Pin 8 Voltage +12 V dc +125 V dc 0 V dc 0 V dc 0 V dc (screen light Z) +45 V dc (screen dark) 0+5 V dc BRIGHTNESS ADJUST 0 V dc 0 V dc

If incorrect, replace the operator panel card assembly. If correct, go to step 4.

Inverter card assembly

Operator panel right cover assembly

Enter the following Menus, Settings, General Settings, and Screen Brightness on the touchscreen display. Enter 22 on the touchscreen display, and Submit the new setting. Measure the voltage at CN1-5. The voltage should measure approximately 0 to +1.5 V dc. Enter 50 on the touchscreen display, and Submit. Measure the voltage at CN1-5. The voltage should measure approximately +2.7 V dc. Enter 100 on the touchscreen display, and Submit. Measure the voltage at CN1-5. The voltage should measure approximately +5.0 V dc. If the voltages do not change when going from 22 to 100 on the display, replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64. If this does not fix the problem, replace the LCD inverter card assembly. See LCD inverter card assembly removal on page 4-108.

Diagnostic information

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LCD touchscreen display lights up, icons displayed, but it does not work when touched.
FRU 1 LCD touchscreen display/ 4-pin cable Action Check the 4-pin display to operator panel card cable for correct installation to J3 on the operator panel card. Note: This cable is a short ribbon cable that can easily become disconnected from J3 on the operator panel card. If the cable is properly installed, go to step 2. If the cable is connected properly to J3, replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64. If this does not fix the problem, replace the LCD touchscreen display assembly. See LCD touchscreen removalmodel 500s on page 4-67. Check the voltages on CN1-1 and CN1-2. They should measure approximately +12 V dc.
Inverter card Connector Cn1 (to operator panel card) Pin number CN1Pin 1 CN1Pin 2 CN1Pin 3 CN1Pin 4 CN1Pin 5 CN1Pin 6 CN1Pin 7 CN1Pin 8 Voltage +12 V dc +125 V dc 0 V dc 0 V dc 0 V dc (screen light Z) +45 V dc (screen dark) 0+5 V dc BRIGHTNESS ADJUST 0 V dc 0 V dc

LCD touchscreen display Operator panel right cover assembly

Inverter card

If incorrect, replace the operator panel card assembly. If correct, go to step 4.

Inverter card assembly

Operator panel right cover assembly

Enter the following Menus, Settings, General Settings, and Screen Brightness on the touchscreen display. Enter 22 on the touchscreen display, and Submit the new setting. Measure the voltage at CN1-5. The voltage should measure approximately 0 to +1.5 V dc. Enter 50 on the touchscreen display, and Submit. Measure the voltage at CN1-5. The voltage should measure approximately +2.7 V dc. Enter 100 on the touchscreen display, and Submit. Measure the voltage at CN1-5. The voltage should measure approximately +5.0 V dc. If the voltages do not change when going from 22 to 100 on the display, replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64. If this does not fix the problem, replace the LCD inverter card assembly. See LCD inverter card assembly removal on page 4-108.

2-152 Service Manual

Main drive service check

Service tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or system board. Warning: Whenever the gearbox assembly is removed from the machine it must be handled very carefully. Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage. It is also very important not to let any dirt, paper, staples, or other material come intact with the grease in the gearbox assembly. Action Remove the controller board and run a Diagnostic Print Test in the continuous mode. Check the main drive assembly for any excessive noise or vibration. Determine if the noise is in the main drive, toner cartridge, fuser, or main drive gearbox. Look for any loose or worn parts in the developer drive assembly, main drive gearbox, or fuser. Repair as necessary. A service error code 936 - Transport Motor may be displayed. Check the voltage at J20-6 on the system board. It measures approximately +5 V dc when the motor is not running and goes to 0 V dc when the motor is running. If incorrect, replace the system board. If this does not fix the problem, replace the main drive motor. Check the continuity of the main drive motor cable. If incorrect, replace the cable. Check the voltages at J20 on the system board.
Pin Static J20-11 J20-8 J20-7 J20-6 J20-5 J20-4 J20-1 +5 V dc +5 V dc +5 V dc +5 V dc +5 V dc +5 V dc Voltage When main drive motor is running +24 V dc 0 V dc 0 V dc +2.5 V dc 0 V dc +5 V dc 0 V dc

FRU 1 Main drive assembly (excessive noise or vibration)

Main drive motor assembly (excessive noise, gears ratcheting and so on)

3 4

Main drive motor cable Motor gear does not turn, no 936 error code or 201.xx Paper Jam user message displays.

If the voltage is incorrect, replace the FRUs in the following order: Main drive motor assembly System board

Diagnostic information

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Operator panel Help and Home buttons service checkmodel 500s

Note: Run the Button Test from the Diagnostics Menu to determine if the buttons are operating properly. See Button Test on page 3-8.

FRU 1 UICC card #1 to UICC card #2 cable (UICC 4-pin cable) UICC card #1 to UICC card #2 cable (UICC 4-pin cable) Bezel assembly

Action Check the UICC 4-pin cable for correct installation to J15 on UICC card #1 and to J1 on UICC card #2. If installed correctly, go to step 2. Check continuity of the UICC 4-pin cable. If correct, go to step 3. If incorrect, replace the cable. Replace the bezel assembly which has UICC card #2 attached. If this does not fix the problem, replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64.

Operator panel Menu button service checkmodel 450S

Note: Run the Button Test from the Diagnostics Menu and check the button for proper operation. See Button Test on page 3-8. FRU 1 UICC card # 1 to UICC card #3 cable (UICC 8-pin cable) UICC card #1 to UICC card #3 cable (UICC 8-pin cable) Operator panel left cover assembly Action Check the cable for correct installation to J1 on UICC card #3 and to J14 on UICC card # 1 (operator panel card). If installed correctly, go to step 2. Check continuity of the UICC 8-pin cable. If correct, go to step 3. If incorrect, replace the cable. Replace the operator panel left cover assembly. See Operator panel left cover assembly removal on page 4-61. If this does not fix the problem replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64.

Operator panel right cover assembly service check

Operator panel LED off. FRU 1 UICC 18-pin operator panel to scanner control card cable UICC 18-pin operator panel to scanner control card cable Scanner control card Scanner control card Action Check to make sure the cable is correctly connected to J10 on the operator panel card and to J15 on the scanner control card. If the cable is correctly connected, go to step 2. Check the cable for any signs of damaged or bent pins. If incorrect, replace the cable. If correct, go to step 3.

Measure the voltage at J15-17 and J15-18. The voltage should measure approximately +24 V dc. If incorrect, replace the scanner control card. See Scanner control card removal on page 4-48. If correct, replace the operator panel right cover assembly. See Operator panel right cover assembly removal on page 4-64.

2-154 Service Manual

Options service check

Service tip: When you have a problem with any of the options installed in the options slots on the system board, switch the non operating option to one of the other option slots to isolate the failure.

Flash memory option(s)

Run a copy of the test page and check to see if the option you are checking is listed. The printer does not recognize the option being installed if the option is not listed. Make sure the memory card is installed correctly and is not broken or damaged. If the memory card is correctly installed and not broken or damaged then run the Flash Test on page 3-17. If the test fails, replace the Flash card. If the problem continues, replace the controller board.

DRAM memory option(s)

This service check is the same as the flash memory option service check with the following exception: Run the DRAM Test on page 3-9 from the menu if the SDRAM Memory card is correctly installed and not broken or damaged. If the test fails, replace the SDRAM card. If the problem continues, replace the controller board.

Hard disk option

Service tip: model 500S supports one hard disk option. Make sure only one hard disk option is installed. Make sure the fixed disk and the fixed disk board are correctly installed. Run the Quick Disk Test on page 3-16 from the Device Test on the Diagnostics menu when a problem is suspected either with the hard disk system board or with the hard disk. Note: The Quick Disk Test is a non-destructive test and indicates Pass or Fail. If the test fails, replace the hard disk. If a problem still exists, replace the hard disk board. The Disk Test/Clean on page 3-16 is used to help restore the disk if the disk contains bad data and is unusable. This test is divided into a cleaning and a verifying or testing section. Warning: This can be a very lengthy 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.

Error Code 976.xx - Network Card x (x=Network card 1, 2, or 3)

A 976 error code indicates an unrecoverable software error in network card x. Verify that network card x is correctly installed in the socket on the interconnect card and is properly grounded. If you find no problem, contact your next level of support before replacing the network card.

Error Code 977.xx - Network Card x

A 977 error displays when the RIP software detects that a network card is installed in slot x on the interconnect card but cannot establish communications with the network card.

Diagnostic information

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Output bin sensor standard tray service check

Service tip: If the output bin standard tray fills up and the bin full sensor fails to post the Remove Paper Standard Bin message:

1. 2. 3. 4. 5.

Enter the Diagnostics Mode. Select Output Bin Tests. Select Sensor Tests. Select Standard Bin. Check the sensor and flag for proper operation.

If you find no problem with the sensor and flag, continue with the service check. Service tip: Be sure the flag is correctly installed. The output bin sensor is a normally closed sensor with the sensor flag down. Therefore, unless the flag is in the up position or out of the sensor slot, a Remove Paper Standard Bin message does not display. FRU 1 System board Printer fails to display Remove Paper Standard Bin message. Output Bin Sensor Test fails. Output bin sensor flag Action Check the voltage at J6-1. It measures +5 V dc when the flag is in the sensor, and 0 V dc when the flag is out of the sensor. If the voltage does not change, replace the sensor cable assembly. If this does not fix the problem, replace the system board.

Make sure the correct flag is installed. Check the flag for damage or improper operation. If incorrect, replace the flag. Note: A broken or improper operating sensor flag causes a Remove Paper Standard Bin message to display before POST completes and cannot be cleared.

Paper feed service checkprinter

If you have a 936 Transport Motor Error go to Main drive assembly removal on page 4-113. FRU 1 Alignment assembly Action Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight. Check the alignment assembly for worn rollers, contaminated rollers, or binds. Replace the alignment assembly if any problem is found. Check the inner paper deflector for correct installation. If the deflector is bowed or not fitting correctly, replace the deflector.

Inner deflector

2-156 Service Manual

Autocompensator fails to feed paper. Failures occur randomly throughout the stack of paper
FRU 1 Pass thru sensor Autocompensator assembly Wear strips in tray x problem is found. Action Check the pass thru sensor for correct installation and operation. The autocompensator pick roll shaft assembly is not providing enough torque if the pick rollers are not picking the paper correctly. Replace the autocompensator assembly. Check the wear strips for excessive wear, scratches, or rough spots. Replace the wear strips if a problem is found.

Paper feed failures occur only near the top of the stack of paper
The most common cause of this problem is paper curl. Remove the paper from tray x and check for the natural curvature in the paper. Reinstall the paper in the correct manner. If the problem persists, it may be necessary to reduce the stack height. Replace both pick rolls if the paper appears to be flat in the tray but there is still a problem.

Failures occur mainly near the bottom of the stack of paper

The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly contact the paper. Also the autocompensator motor may be failing. If this problem continues replace the autocompensator assembly.

Double feeding paper

Note: If double feeding paper occurs mostly from the bottom of the stack, check for missing or damaged restraint pads in the tray. FRU 1 Paper Action Paper is usually the primary cause of a double feeding paper problem. Flex the paper before placing the paper in the tray. Edgewelded paper is the most common cause of double feeding. Loading the paper in the tray in different locations and directions and using rough paper and short grain paper also causes double feeding. Make sure the counterbalance spring is not missing, loose, or broken at the top of the autocompensator arm assembly. If you find a problem, replace the autocompensator assembly.

Autocompensator

Paper fails to feed from the multipurpose tray

The pick roll should make one complete revolution and stop with the flat side down. If the pick roll turns but does not pick paper, check the roll for signs of wear, oil or grease on the surface of the pick roll or slick spots. If you find a problem, replace the pick roll assembly. Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications.

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Paper size sensing service check

Before proceeding, check for the correct paper size loaded in the tray and that the tray has been set to accept the size paper loaded in the tray.

SW2 SW1 SW0

CN1 1

Paper size sensing switch chart

ITC CN1 pin 1 2 3 4 Signal PSIZE2 Ground PSIZE1 PSIZE3 ITC switch SW1 Ground SW0 SW2 X X X X X X Paper tray size selection (X is activated) Letter X Legal X A4 Exec B5 X A5 System board J34 pin 1 2 3 4

Tray 1 not recognized as being installed; unable to clear Tray 1 Missing message
FRU 1 Tray 1 Action Check Tray 1 for damaged or broken autosize fingers. Check for anything that would prevent the autosize fingers from activating the paper activate springs and ITC switches.

LGL

A4

LTR EXEC B5 A5

2 1

S S

If a problem is found, repair or replace the tray assembly. If no problem is found, go to step 2.

Integrated card/ autocompensator cable System board

Check for correct installation of the cable at J26 on the system board. If installed correctly, go to step 3. If incorrectly installed, install and recheck the printer. Check the continuity between J26-2 on the system board and ground. It should measure approximately 0 ohms.

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The printer does not recognize the paper size selected

FRU 1 Back restraint Side restraint Snap-in plate Autosize slider Autosize finger Switch activate spring Paper size sending board System board ITC cable Action Check all the paper size parts for damage or broken parts. make sure the parts operate correctly. If a problem is found, repair as necessary. If no problem is found, go to step 2.

2 3

Make sure the switch activate spring is not bent or broken. Replace the spring if damaged. If the spring is not damaged, go to step 3. Set the tray for the paper size that is not recognized and install the tray in the printer. Select the paper size and corresponding paper switch from table, below.
Pin Signal J26 1 2 3 4 5 6 7 8 9 10 +3.3 +3.3 +3.3 PSIZE2 Ground PSIZE1 PSIZE3 Static tray out (V dc) +3.3 0 +3.3 +3.3 Static with paper tray in and set to: (V dc) Letter 0 0 +3.3 0 Legal 0 0 +3.3 +3.3 N/A N/A N/A +3.3 N/A N/A +3.3 +3.3 +3.3 +3.3 A4 +3.3 0 0 +3.3 Exec +3.3 0 0 0 B5 0 0 0 +3.3 A5 +3.3 0 +3.3 0

If the voltage on J26 does not change, go to step 4. If the voltage changes, recheck the printer. If Tray 1Missing is still displayed, replace the system board assembly.

System board

Ground the appropriate pin on connector J26 on the system board. Tray 1 Missing should not be displayed. If it is not displayed, go to step 5. If it still displays, replace the system board assembly. Check continuity of the autocomp cable. If correct, replace the ITC assembly. If incorrect, replace the autocomp cable.

Autocomp cable

Parallel port service check

Run the Parallel Wrap test on page 3-10. Note: The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug (P/N 1319128) and invoking the Parallel Diagnostic Test. This test helps isolate the printer from the parallel cable and host. The test provides failure information on the display for approximately three seconds. If the test indicates that a problem is detected, replace the controller board.

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Print quality service check

Service tip: Before troubleshooting any print quality problems do the following:

Install another print cartridge if available before proceeding with the service checks. Use Tray 1 to test for print quality of the printer. Replace the charge roll if it is damaged or contaminated. Replace the transfer roll if it is damaged or contaminated. Make sure the fuser assembly is installed correctly. Verify proper paper type, texture, and weight settings for the media being used. Test the printer using plain paper (20 lb).

Select the following menu settings as indicated. Be sure and note the original settings so you can return the printer to the original customer printer setup.

Print Resolution: Set to 300 dpi (print quality problems should be checked at different resolution settings). Print Darkness: Set to NORMAL. Toner Saver: Set to OFF. PQET: Set to OFF. Fuser Temperature: Set to NORMAL. Test the printer using plain paper (20 lb).

An incorrect printer driver for the installed software can cause problems. Incorrect characters could print, and the copy may not fit the page correctly. Measure all voltages from the connector to printer ground. All voltages measured during the print cycle are measured with the controller board removed while running the print test.

Print qualityall black page

Service tip: An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum. FRU 1 High voltage contacts Action Check the high voltage contacts on the right side frame to ensure they fit securely and are not pitted, contaminated, or damaged. If incorrect, replace the contact with one from the HV contact kit. Screws and plastic blocks are included to attach the contacts to the right side frame in the HV contact kit. Make sure the charge roll bushing is correctly installed in the right charge roll arm. Check the voltages on J15-1 thru J15-8. If incorrect, replace the system board.

2 3

Charge roll conductive bushing HVPS

HVPS cable (part of front harness cable) System board

Check the continuity of the HVPS cable. If incorrect, replace the cable assembly. If correct, replace the system board.

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Print qualityblank page

FRU 1 Print cartridge High voltage contact Action Check the print cartridge for damage, especially the PC drum contact on the cartridge. Check the PC drum contact on the right side frame for damage, PC drum contact wear or contamination. If the contact is bent or damaged, replace the contact. Note: Inspect the HVPS PC drum contact on the board for damage or contamination. Check the fuse on the HVPS. If open, replace the HVPS. Check the voltages at J22 on the system board. Measure the following voltages from connector J22 to printer ground: Printer Idle J15-5 measures +24 V dc Printer Printing J15-5 measures +24 V dc If the voltages at J10-5 are incorrect, replace the system board. Check the front cable harness at J15 on the system board and at CN1 on the HVPS to make sure the harness is connected properly. If connected properly, check the continuity of the cable harness. If there is no continuity, replace the front cable harness. Generally a 93x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom. The printhead used in the printer does not have a mechanical shutter as previous laser printers. The printer is interlocked through the front top cover interlock switch.

HVPS

Front cable harness HVPS section

Printhead assembly

Print qualityrandom marks

Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor, charge roll, or transfer roll. Symptom 1 Random marks Action Check the print cartridge for loose or foreign material that might be on the photoconductor. Check the transfer roll and charge roll for any pieces of material that are stuck to the rolls.

Print qualityblurred or fuzzy print

Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly, alignment assembly, any feed roller, or in the transfer roll bearings or transfer roll. Check the gearbox assembly for correct operation. Check the transfer roll for binds or a contaminated shaft or bearings. Blurred print can also be caused by incorrect feeding from one of the input paper sources, paper trays, duplex option, or envelope feeder. Check the high voltage contacts to ensure they are not bent, corroded, or damaged. Replace as necessary.

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Print qualitybackground
Service tip: Some background problems can be caused by rough papers, non-Toshiba toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background problems. Some problems occur with printers that run a large amount of graphics in a humid environment. The customer may try to improve the print quality by increasing the transfer setting. Check the charge roll to make sure it is not at the end of life. FRU 1 Printhead Transfer roll assembly Action The printhead on this printer cannot be cleaned. Try another printhead if all other attempts fail to correct a background problem. Check the high voltage contact from the HVPS to the transfer roll. Check the transfer arm assembly right side bearing for contamination, pitting, or a loose cable to the bearing. If any problems are found, replace the defective part. Check the transfer roll shaft for contamination, wear, or pitting on the ends of the shaft that go into the bearings. If a problem is found, clean the ends of the shaft or replace the transfer roll assembly. Check the high voltage contacts on the right side frame to ensure they are clean and not bent, deformed, or pitted. If incorrect, replace the contact. Check the following voltages at J15 on the system board. Measure the voltages from J15 to printer ground.
Pin J15 Printer idle J15-1 J15-2 J15-4 J15-1 J15-2 J15-4 0 V dc +4 V dc 0 V dc 0 V dc to +5 V dc 0 V dc to +4 V dc 0 V dc to +1.9 V dc Voltage (approximate)

High voltage contacts

System board HVPS connector

Printer printing

If J15-1 voltage is incorrect, check the continuity of the front harness cable (J15-1 line). If there is no continuity, replace the harness cable. If there is continuity, replace the HVPS. If this does not correct the problem, replace the system board. If J15-2 voltage is incorrect or if the voltage remains at 0 V dc, check the continuity of the front harness cable (J15-2 line). If there is no continuity, replace the harness cable. If there is continuity, replace the HVPS. If this does not correct the problem, replace the system board. If J15-4 voltage is incorrect, check the front harness cable (J15-3 line). If there is not continuity, replace the harness cable. If correct, replace the system board. If this does not correct the problem, replace the HVPS.

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Print qualitybanding
Service tip: Banding is difficult to detect, except on a page with a uniform gray or a large amount of graphics printed on the page. Banding is primarily due to a variation in the speed of the paper as it feeds through the printer, especially in the development and transfer process. Inspect the alignment assembly, main drive assembly, and all other paper feed components for signs of wear, dirt, binds, or damage, especially the drive gears. Banding appears as light or dark horizontal lines on a uniformly gray page. Banding can also be caused by a defective charge roll brush contact or HVPS. Check the charge roll contact for damage and for proper connection to the HVPS and print cartridge.

Print qualityblack bands on outer edges of the page

This print quality problem appears as vertical black bands on one or both sides of the copy and can be wide, narrow, light, or dark. FRU 1 Charge roll counterbalance springs Action If the problem is just on one side of the page, check the charge roll counterbalance spring on that side. You can check to see if enough force is being applied to the charge roll by applying slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample. See if the problem changes or goes away. If this fixes or changes the problem, then check the springs and charge roll link arm assemblies for binds or defective parts. Replace as necessary. Check the charge roll for toner buildup or other contamination on the outer edges that correspond to the bands on the page. Check the charge links and arms for proper operation, binds or incorrectly mounted counterbalance springs. Repair or replace as necessary. Check the following voltages at J15-8 on the system board: Printer Idle J15-8 measures 0 V dc Printer Printing Test Page J15-8 voltage changes from 0 V dc to +4 V dc If the voltage does not vary, check the continuity of line J15-8 in the front cable harness. If there is no continuity, replace the cable harness. If there is continuity, replace the HVPS. If this does not correct the problem, replace the system board. Turn the printer off, and check the resistance between J15-7 and printer ground. The resistance measures approximately 0 ohms. If incorrect, make sure the system board is mounted correctly and securely grounded. If correct, replace the system board.

Charge roll assembly Charge roll link arm

HVPS

Print qualityresidual image

Service tip: Install a new print cartridge if available before doing this service check. Residual image can be caused by the photoconductor, cleaning blade, and other parts inside the print cartridge. FRU 1 Hot roll fuser assembly Action Check the fuser assembly for toner contamination. The hot roll especially might cause toner to be retained and deposited on the page.

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Print qualitylight print

Service tip: Check the toner saver and print darkness settings first if the print is light. FRU 1 Transfer roll Right side transfer roll arm assembly HVPS Action Check the right end of the transfer roll shaft for signs of wear or contamination. If incorrect, replace the transfer roll. Check the right side transfer roll arm assembly bearing for wear or contamination. Also make sure the transfer cable is firmly attached to the bearing. If incorrect, replace the right side transfer arm assembly. Check the connection of the transfer roll assembly cable to the transformer on the HVPS board. Check the continuity of the cable from the bearing to the spade terminal on the cable. If incorrect, replace the right side transfer arm assembly. If correct, replace the HVPS. If the printer is not already at 1200 dpi, change the Print Resolution setting to 1200 dpi and see if the darkness level changes: 1. In Ready state, press Menu. 2. Select Settings, and press Select. 3. Select Quality Menu, and press Select. 4. Select Print Resolution, and press Select. 5. Select 1200 dpi. 6. Press Back until Ready appears. 7. Print a test page (if you want to print an internal test page, Print Fonts is the only internal 1200 dpi document). If printing in 1200 dpi is correct and not light, but other printing at other dpi settings print light, there may be damage to the printhead cables. Check the printhead cables for any signs of damage. Check the area of the wire tie on the printhead laser cable for damage. If damaged, replace the cable. If not damaged, go to step 3 A contaminated printhead may be the cause of light print. If no other cause is found, install a new printhead. See Printhead removal on page 4-127.

Printhead cable

Printhead

Print qualitytoner on backside of printed page

Service tip: This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper. FRU 1 Hot roll fuser assembly Action Toner is being carried out on the backside of the media. This problem is generally caused by a toner buildup on the fuser hot roll or backup roll. Check the fuser hot roll and backup roll for any noticeable buildup of toner. Repair as necessary. Check the transfer roll for toner buildup or loose toner around the area of the transfer plate assembly. Clean the area and run another copy. If the problem continues, replace the FRUs in the following order: HVPS System board

Transfer roll transfer plate assembly

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Printhead service check

CAUTION The printhead is not a serviceable FRU. Do not disassemble the printhead.

The printhead assembly does not contain any service replaceable parts or components. If service error code 930.xx displays, the wrong printhead is installed in the printer. See Printhead on page 7-24. Note: A 201.xx paper jam may also indicate a failing printhead. The paper may have jammed prior to or at the input sensor. Print the event log and see if 201 or 931 errors are logged. Service error code 1 Error code 931.xx No first HYSNC Signal Error Code 932 Lost HYSNC Explanation These errors usually indicate a failure in the HYSNC signal to the printhead. Check the continuity of the cables connected to J2 and J4 on the system board. If incorrect, replace the defective cable. The voltage at J4-1 measures approximately +5 V dc. If incorrect, replace the system board. The voltage at J2-7 measures approximately +24 V dc. If incorrect, replace the system board. If correct, replace the printhead assembly. See Printhead removal on page 4-127. These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the system board cable or system board assembly. The voltage at J5-2 measures approximately +24 V dc. If incorrect, replace the system board. If correct, replace the FRUs in the following order: System board. See System board and inner shield removal model 450S on page 4-130 or System board and inner shield removal model 500S on page 4-131. Printhead assembly See Printhead removal on page 4-127.

Error Code 934.xx Mirror motor lost lock Error Code 935 Mirror motor unable to reach operating speed

Scan quality service check

Determine if the problem is in the scanner assembly or in the base printer. Enter the Diagnostic Menu and select Print Quality Test Pages. Make sure the printer is set to specifications before using the test pages on the scanner. Check the test pages to help determine if the problem is in the base printer or the scanner. If the problem is in the scanner, ADF, or flatbed use the test pages to help isolate the problem in the appropriate scanner assembly and continue with this service check. If the problem is in the base printer, see Print quality service check on page 2-160.

Vertical streaks or lines on image

Note: Perform the Cleaning the scanner glass, cushions, and strips on page 6-2 before proceeding with this service check. Note: Vertical streaks can be caused by debris in the optical path of the CCD module(s). Check for any signs of pieces of media or other debris in or around the ADF CCD, flatbed contact glass, or flatbed CCD. FRU 1 Models X644e, X646e Action If you do not have one of these models, to step 2. If the vertical streaks only occur with the ADF scanner assembly, go to step 3. If the streaks are in the flatbed scanner assembly, go to step 7. Go to step 7.

Model X642e

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FRU

Action Check for any signs of contamination on the ADF CCD module glass. Use a clean, soft lint-free cloth with isopropyl alcohol (if available) to clean the glass if any contamination is found. Note: The ADF module glass can be accessed by removing the flatbed white cushion from the ADF and lower the exit guide assembly. If the problem persists go to step 4. Check the lower exit guide backside assembly for any signs of damage to the back ADF white cushion or hardware.
Model 500S

ADF CCD module glass (model 500S)

Lower exit guide assembly (model 500S)

If the back ADF white cushion cannot be cleaned properly, is damaged, or is missing, replace the lower exit guide assembly. See Lower exit guide assembly removal on page 4-47. If no problem is found with the lower exit guide assembly, go to step 5.

ADF frontside bracket assembly strip

Check the ADF frontside bracket assembly for any signs of damage to the front flatbed white strip. If damaged, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. If no problem is found, check the front flatbed white strip for any signs of dirt, debris, or contamination. If any problem is found, clean the strip with a clean, soft, lint-free cloth with isopropyl alcohol (if available). If this does not fix the problem, or no problem is found, go to step 6. Replace the ADF CCD module assembly. See ADF CCD module assembly removal (model 500S) on page 4-14.

ADF CCD module assembly

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FRU

Action Check for any signs of contamination on the flatbed contact glass.

Flatbed contact glass (both models) )

Use a clean, soft, lint-free cloth with isopropyl alcohol (if available) to clean the glass of any contamination. If the problem still persists, go to step 8. Note: It is recommended that you remove the glass and clean both sides.

Flatbed glass holder assembly (models X642e/X644e/ X646e) ADF frontside bracket assembly strip

Check for any signs of contamination of the flatbed glass holder. Use a clean, soft, lint-free cloth with isopropyl alcohol (if available) to clean the glass if any contamination is found on the glass. If after cleaning, the problem persists, go to step 9. Check the ADF frontside bracket assembly for any signs of damage to the front flatbed white strip. If damaged, replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. If no problem is found, check the front flatbed white strip for any signs of dirt, debris, or contamination. If any problem is found, clean the strip with a clean, soft, lint-free cloth with isopropyl alcohol. If this does not fix the problem, or no problem is found, go to step 10. Replace the flatbed CCD module. See Flatbed CCD module assembly removal on page 4-28.

10

Flatbed CCD module (models X642e/X644e/ X646e)

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All black or blank image

This symptom may be caused by insufficient illumination from the lamps in the CCD, a defective CCD, or an electrical problem. FRU 1 Determine which portion of the scanner has the problem. ADF CCD module to the interconnect board cable (model 500S) Action If the problem is with the ADF portion of the scanner assembly, go to step 2. If the problem is with the flatbed scanner assembly, go to step 6. Check the 36-pin flatbed interconnect board to ADF CCD module cable to make sure it is connected properly to both the CCD module and the flatbed interconnect board. If it is not connected properly, reconnect and recheck the MFP. If the problem is still present, go to step 3. Check the cable to make sure it is properly connected to both the flatbed interconnect card and to the scanner control card. If it is properly installed, check the cable for any signs of damage, bent pins, or so forth. If any damage is found, replace the complete ADF scanner assembly. See ADF complete assembly removal on page 4-15. If no problem is found, go to step 4. Check the cable to make sure it is properly connected to both the flatbed interconnect card and to the scanner control card. If it is properly installed, check the cable for any signs of damage, bent pins, or so forth. If any damage is found, replace the complete ADF scanner assembly. See ADF complete assembly removal on page 4-15. If no problem is found, go to step 5. Replace the ADF CCD module. See ADF CCD module assembly removal (mode l500S) on page 4-14. If this does not fix the problem, replace the following FRUs in the order listed: Flatbed interconnect card Scanner control card Check the cable to make sure it is properly connected to both the flatbed CCD module and to the flatbed interconnect card. If properly installed, check the cable for any signs of damage, ben pins, and so forth. If any damage is found, replace the cable. If no problem, is found, go to step 7. Replace the flatbed CCD module. See Flatbed CCD module assembly removal on page 4-28. If does not fix the problem, replace the scanner control card. See Scanner control card removal on page 4-48.

ADF CCD module to the interconnect board cable (model 500S)

Flatbed interconnect board (CN5) to scanner control card (J28) cable. (model 500S)

ADF CCD module (model 500S) Flatbed interconnect card Scanner control card Flatbed CCD module to flatbed interconnect board (J2) cable

Flatbed CCD module

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Line compression
Note: This problem is usually caused by shocks of media entering or exiting any roller pairs. FRU 1 Media Action Measure the distance from the leading or training edge of the media to the compression. If the distance is approximately 53mm from the leading edge, go to step 2. If the distance is approximately 57mm from the leading edge of the media, go to step 3. If the distance is approximately 137mm from the training edge of the media, go to step 4. This can be caused by the impact of the media entering the second scan area. Replace the lower exit guide assembly. See Lower exit guide assembly removal on page 4-47. This can be caused by the shock of the media being released from the first scan roller. Replace the complete ADF assembly. See ADF complete assembly removal on page 4-15. This can be caused by the shock of paper release from the feed/ separator roller. Replace the following FRUs in the order listed: Pick mechanism. See ADF pick assembly removal on page 4-7. Separator assembly. See Separator assembly torque limiter removal on page 4-52. This problem can be caused by flatbed motor vibration and will usually appear at the left or right edges of a scan. Replace the following FRUs in the order shown: Flatbed CCD module Flatbed scan motor

Lower exit guide assembly

ADF assembly

Pick mechanism Separator arm

Flatbed CCD module

Wavy lines
Wavy lines seen only on flatbed text or mixed mode up to 300 dpi scans. FRU 1 Flatbed CCD module assembly Action Replace the flatbed CCD module assembly. See Flatbed CCD module assembly removal on page 4-28. If the problems continue, replace the flatbed scan motor. See Flatbed scan motor assembly removal on page 4-41.

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Signature button assembly service check

Note: If you are unable to clear a 32.xx-Unsupported Cartridge User Error message, be sure a Lexmark T64x print cartridge is correctly installed in the printer. The cartridge is easily identified by the contact board on the right side rear of the cartridge. Install another print cartridge before attempting to troubleshoot the printer. Make sure the signature button cable is properly connected to J14 on the system board. Check the print cartridge for damage or improper installation of the chip. Also, be sure there is proper contact between the chip on the cartridge and the signature button contact assembly. Service tip: An intermittent 32.xx-Unsupported Cartridge User Error message can be caused by poor contact between the signature button cartridge contacts in the upper front cover and the chip. Also check for proper seating of the signature button cartridge cable to the system board. FRU 1 Signature button contact assembly System board Action Check the voltage on the signature button cartridge contact. The voltage measures approximately +3.8 V dc when not writing data to the system board. If data is being written, the voltage measures approximately 0 V dc. If incorrect, disconnect the cable from J19 on the system board, and check the voltage on J19-1. The voltage measures approximately +5 V dc. If incorrect, replace the system board. If correct, replace the signature button cartridge contact assembly.

System board service check

Warning: When replacing any one of the following components:

Flatbed interconnect card (ICC) System board assembly Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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.

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Toner sensor service check

Service tip: Check the print darkness menu setting before checking the toner sensor. This service check is intended to be used when a 929.xx Service Error displays. FRU 1 Developer drive assembly Action Incorrect operation of the developer drive assembly can cause the printer to display a 929.xx error code (Toner Sensor). Check the developer drive assembly for correct installation or, any sign of worn, loose, or broken parts. Check the toner sensor portion of the front harness cable to make sure it is properly seated into the toner sensor. If correct at both the sensor and system board (J15), check the continuity of the cable. If incorrect, replace the cable. The toner sensor cable is part of the front harness and part of connector J15 on the system board. Check the voltage at J15-11. It reads approximately +5 V dc. If incorrect, replace the system board. If correct, check the voltage at J15-12. It reads approximately +5 V dc with the system board removed from the printer. If incorrect, replace the system board. If correct, replace the toner sensor assembly. A bad ground connection between J15-13 on the system board and pin 3 on the toner sensor results in a 929 service error.

Front harness cable

Toner sensor

Diagnostic information

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Transfer roll service check

Service tip: The transfer roll is 51.02 mm (2.009 inch) circumference. Any print quality problems such as lines that are spaced 51.02 mm apart indicate you should check the transfer roll for damage and check for toner or foreign material buildup. Service tip: The transfer roll assembly is part of the maintenance kit and is replaced when an 80 Scheduled Maintenance displays. Ask the customer if they have replaced the transfer roll recently. CAUTION Make sure the printer is unplugged before making any checks on the transfer roll or associated parts for personal safety and to prevent damage to the printer.

FRU 1 Transfer roll assembly

Action Check the transfer roll for toner buildup, surface damage to the roll, oil, or other contaminants on the surface of the roll. Replace the transfer roll as necessary. Check the left transfer roll arm assembly to make sure it is fastened and locked in the down position. If the arm is not locked down, make sure the arm is not broken and locks into the EP frame correctly. Check the left transfer arm assembly spring for proper operation. Check the right transfer arm assembly to make sure it is fastened and locked in the down position. If the arm is not locked down, make sure the arm is not broken and locks into the EP frame correctly. Check the right transfer arm assembly spring for proper operation. For any background problems, ensure the contact to the HVPS board is correct and that there is approximately 0 ohms resistance between the transfer roll shaft and the HVPS contact. If correct, go to Print qualitybackground on page 2-162 Check the voltage at J15-3. The voltage changes from +24 V dc with the printer idle to 0 V dc when the printer runs the print test. If the voltage is incorrect, check the continuity of line J15-3 in the front cable harness to the HVPS. If there is no continuity, replace the cable harness. If there is continuity, replace the HVPS. If the problem continues, replace the system board.

Left transfer arm assembly

Right transfer arm assembly

HVPS917 Error code

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3. Diagnostic aids
This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem.

Accessing service menus

There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics Menu 1. Turn off the printer. 2. Press and hold the 3 and 6 buttons simultaneously for about 10 seconds. 3. Turn on the printer. 4. Release the buttons after 10 seconds. The Diagnostics Menu group consists of menus, settings, and operations that are used to diagnose various printer problems. Note: While the Diagnostics menu group is active, all host interfaces are offline. See Diagnostics Menu on page 3-2 for more information.

Configuration Menu

1. Turn off the printer. 2. Press and hold the 2 and 6 buttons simultaneously for about 10 seconds. 3. Turn on the printer. 4. Release the buttons after 10 seconds.

The Configuration Menu group contains a set of menus, settings, and operations which 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 (CONFIG MENU) on page 3-24 for more information.

Diagnostic aids

3-1

Diagnostics Menu
Entering Diagnostics Menu
1. Turn off the printer. 2. Press and hold 3 and 6 buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds.

Available tests
The tests display on the operator panel in the order shown: Note: Some menus are not available, depending on the configuration of the printer.

Diagnostics Menu tests

REGISTRATION Top Margin Bottom Margin Left Margin Right Margin Quick Test PRINT TESTS Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) MP Feeder Envelope Feeder (if installed) Printing Print Quality Test Pages HARDWARE TESTS Panel Test Button Test DRAM Test CACHE Test Parallel 1 Wrap (if installed) (Note: This setting only appears if a parallel port is available through the PCI slot 1) Serial 1 Wrap (if installed) (Note: This setting only appears if a serial port is available through the PCI slot 1) See Parallel Wrap test on page 3-10 See Panel Test on page 3-8 See Button Test on page 3-8 See DRAM Test on page 3-9 See Printing Quality Pages on page 3-7 See Input source tests on page 3-7 See Quick Test on page 3-6 See Registration (printer) on page 3-5

See Serial Wrap test on page 3-10

3-2 Service Manual

Diagnostics Menu tests (continued)

DUPLEX TESTS (if installed) Quick Test Top Margin Sensor Test Motor Test Duplex Feed 1 Duplex Feed 2 INPUT TRAY TESTS Feed Tests Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) Envelope Feeder MP Feeder Sensor Tests Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) Envelope Feeder MP Feeder OUTPUT BIN TESTS Feed Tests Standard Bin Sensor Tests Standard Bin BASE SENSOR TEST Toner Sensor Input Sensor Standard Bin Sensor Upper Front Cover Narrow Media DEVICE TESTS Quick Disk Test (model 500S) Disk Test/Clean (model 500S) Flash Test (if flash is installed) See Quick Disk Test on page 3-16 See Disk Test/Clean on page 3-16 See Flash Test on page 3-17 See BASE SENSOR TEST on page 3-15 See OUTPUT BIN TESTS on page 3-14 See Sensor Test (input tray) on page 3-14 See Feed Tests (input tray) on page 3-13 See Quick Test (duplex) on page 3-11 See Top Margin (duplex) on page 3-11 See Sensor Test (duplex) on page 3-12 See Motor Test (duplex) on page 3-12 See Duplex Feed 1 on page 3-13 See Duplex Feed 2 on page 3-13

Diagnostic aids

3-3

Diagnostics Menu tests (continued)

PRINTER SETUP Defaults Printed Page Count Perm Page Count Serial Number Envelope Enhance Engine Setting 1 to 4 Model Name Configuration ID Edge To Edge Par S Strobe Adj PAR 1 STROBE ADJ (if additional parallel options are installed) EP SETUP EP Defaults Fuser Temp Fuser Page Count Warm Up Time Transfer Print Contrast Charge Roll Gap Adjust EVENT LOG Display Log Print Log Clear Log SCANNER TESTS ASIC Test Feed test Manual Registration Sensor Tests See ASIC Test on page 3-23 See Feed Test on page 3-23 See Scanner Manual Registration on page 3-23 See Sensor Tests on page 3-23 See Display Log on page 3-21 See Print Log on page 3-22 See Clear Log on page 3-22 See EP Defaults on page 3-20 See Fuser Temperature (Fuser Temp) on page 3-20 See Fuser Page Count on page 3-20 See Warm Up Time on page 3-20 See Transfer on page 3-21 See Print Contrast on page 3-21 See Charge Roll on page 3-21 See Gap Adjust on page 3-21 See Defaults on page 3-17 See Printed Page Count on page 3-18 See Permanent Page Count on page 3-18 See Serial Number on page 3-18 See Envelope Enhance on page 3-18 See Engine Setting 1 through 4 on page 3-18 See Model Name on page 3-18 See Configuration ID on page 3-19 See Edge to Edge on page 3-19 See Parallel strobe adjustment (Par x Strobe Adj) on page 3-19

Touch Exit Diag Menu to exit the Diagnostics Menu and Resetting the Printer displays. The printer performs a POR, and the printer returns to normal mode.
Exit Diag Menu

Exit Diag Menu

3-4 Service Manual

Registration (printer)
Print registration makes sure the printing is properly aligned on the page.
Models X644e/X646e
REGISTRATION Top Margin Bottom Margin Left Margin Right Margin
Quick Test

Model X642e REGISTRATION

0 0 0 0

Top Margin 0 Top Margin 0 Top Margin 0 Top Margin 0

Submit
Submit Back

Back

The settings available are: Description Bottom Margin Value -20 to +20 Each increment causes approximately 0.55 mm shift in the bottom margin. Top Margin -25 to +25 Each increment causes approximately 4 pels shift (at 600 dpi). Left Margin -25 to +25 Direction of change A positive change compresses the image so it appears to move down the page, and a negative change moves the image up. A positive change moves the image down the page and increases the top margin. A negative change moves the image up and decreases the top margin. A positive change moves the image right, and a negative change moves the image left. No compression occurs. A positive change moves the image right, and a negative change moves the image left.

Right Margin

-10 to +10

Diagnostic aids

3-5

To set print registration:

1. Print the Quick Test page. a. Touch REGISTRATION from the Diagnostics Menu. b. Touch to select Quick Test. You may need to scroll to the next page.
Retain this page to determine the changes you need to make to the margins settings. The diamonds in the margins should touch the margins of the page.

2. To change the value of any of the margin settings: Touch

to the right of the appropriate margin setting. The panel displays the setting's name in the [setting's current value] in a menu below the header row. header and

Touch to decrease the value or to increase the value. Touch Submit to save the change, or Touch Back to cancel and return to the Diagnostics Menu. For model X642e, touch Submit to save all changed values.
The device prints a Quick Test page from the appropriate paper tray. While the Quick Test page prints, Printing Alignment Page appears on the LCD.

Quick Test
The Quick Test contains the following information:

Margin settings Alignment diamonds at the top, bottom, and each side. Horizontal lines for skew adjustment General printer information, including current page count, installed memory, serial number, and code level.

To print the Quick Test page: Note: Print the Quick Test Page on letter or A4 paper.

1. Touch REGISTRATION from the Diagnostics Menu. 2. Touch

to select Quick Test. The message Quick Test Printing appears on the display. Once the Quick Test Page completes printing, the Registration screen displays again.

3. Touch Back to return to the Diagnostics Menu.

3-6 Service Manual

PRINT TESTS
Selections on the screen vary since only installed input sources are listed, followed by Printing Quality Test Pages.

Input source tests

The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. The contents of the Print Test Page varies depending on the media installed in the selected input source. Check each Test Page from each source to assist in print quality and paper feed problems. To run the Print Test Page:

1. Select PRINT TESTS from the Diagnostics menu. 2. Select the media source to test:
Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) MP Feeder (if installed) Envelope Feeder (if installed)

3. Select Single or Continuous. If Single is selected, a single page is printed. If Continuous is selected, printing continues until Stop is pressed to cancel the test.
If a source is selected that contains envelopes, an envelope test pattern is printed. If Continuous is selected, the test pattern is printed only on the first envelope. Note: The Print Test Page always prints on one side of the paper, regardless of the duplex setting or the presence of a duplex option. Touch Back to return to PRINT TESTS.

Printing Quality Pages

The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled. The print quality pages consist of four pages. Page one contains a mixture of graphics and text. Pages two and three only contain graphics. The last page is blank. If duplex is turned on, the pages are duplexed. The Print Quality Test pages are printed in English and must always be printed on letter, legal, or A4 paper. To run the Print Quality Test Pages, touch beside Printing Quality Test Pages from PRINT TESTS. The message Printing Quality Test Pages is displayed. Note: The print quality test pages can also be printed from the Configuration menu (CONFIG MENU), however, a cartridge must be installed with a machine class ID matching the machine class ID stored in NVRAM. Additional diagnostic information may be printed on the pages when printing from DIAGNOSTICS.

Diagnostic aids

3-7

The following is included in the DIAGNOSTICS version of the print quality pages:

Values from EP SETUP in DIAGNOSTICS, including:

Fuser temperature, warm up time, transfer, print contrast, and charge roll settings.

Contents of the EVENT LOG from DIAGNOSTICS. Configuration information, including printer serial number, controller code level, engine code level, operator
panel code level, font versions, and cartridge information.

Default values for the QUALITY MENU settings used to print the pages.

HARDWARE TESTS
Select the following Hardware Tests from this menu:

Panel Test Button Test DRAM Test CACHE Test Parallel 1 Wrap (if available)model 500S Serial Wrap (if available)model 500S

Panel Test
This test automatically toggles each pixel of the touchscreen through every contrast level beginning with the darkest and on to the brightest. This test continues until you press Stop ( ).

Button Test
The Button Test verifies the operation of the buttons on the operator panel. When you select Button Test, a diagram of the operator panel appears on the panel. When you press a button on the operator panel, the corresponding touchscreen key is emphasized. Touch Back to cancel the test.
Model 500S Model 450S

1 4 7

2 5 8 0

3 6 9 =

S H

G T

C M

*
<-

.
Back

3-8 Service Manual

DRAM Test
The purpose of this test is to check the validity of DRAM memory, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test:

1. Touch

to select DRAM Test from the menu.

The message DRAM Test Testing displays. Then the message Resetting Printer appears, and the power indicator light blinks red.

2. Turn the printer off and on. While the DRAM test executes, the power indicator blinks green.
The following type of message appears: DRAM Test <### P:###### F:####

xxx represents the installed DRAM size. P:###### represents the number of times the memory test has passed and finished successfully.
Initially 000000 displays with the maximum pass count being 999,999.

F:##### represents the number of times the memory test has failed and finished with errors. Initially
0000 displays with the maximum fail count being 99,999. Initially only four digits appear, but additional digits appear as needed. Each time a test is completed, the number of pass and failures increments. If the test fails, the message Failure displays for approximately three seconds, and the failure count increases by one. The test continues until all standard and optional DRAM is tested. Once the maximum pass count or fail count is reached, the test is stopped, the power indicator is turned on solid, and the final results display. To stop the test before completion, turn the MFP off.

CACHE Test
This test is used to verify the printer processor cache. To run the CACHE Test:

1. Touch

to select CACHE TEST from HARDWARE TESTS.

The message CACHE Test Testing displays. Then the message Resetting Printer appears.

2. The printer automatically performs a Power On Reset (POR). While the CACHE test executes, the power
indicator blinks green. The following type of message appears: CACHE Test <### P:###### F:####

P:###### represents the number of times the cache has passed and finished successfully. Initially
000000 displays with the maximum pass count being 999,999.

F:##### represents the number of times the cache has failed and finished with errors. Initially 0000
displays with the maximum fail count being 99,999. Initially only four digits appear, but additional digits appear as needed. Each time a test is completed, the number of passes and failures increments. If the test fails, the message Failure displays for approximately three seconds, and the failure count increases by one. The test continues until all of the printer processors cache has been tested. Once the maximum pass count or fail count is reached, the test is stopped, the power indicator is turned on solid, and the final results display. To stop this test before completion, turn the MFP off.

Diagnostic aids

3-9

Parallel Wrap test

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

1. Disconnect the parallel interface cable, and install the wrap plug (P/N 1319128). 2. Select Parallel Wrap, Parallel 1 Wrap, or Parallel 2 Wrap from the HARDWARE TESTS menu.
The power indicator blinks green indicating the test is in progress. The test runs continuously until a maximum number of tests is reached. P:###### F:####

P:###### represents the number of times the memory test has passed and finished successfully.
Initially 000000 displays with the maximum pass count being 999,999.

F:##### represents the number of times the memory test has failed and finished with errors. Initially
0000 displays with the maximum fail count being 999,999. Initially only four digits appear, but additional digits appear as needed. Each time the test finishes, the screen updates. If the test passes, the pass counter increases by 1, however if the test fails, a message displays for approximately three seconds. Once the maximum count is reached, the test stops. The power indicator goes on solid, and the final results display. To stop the test before completion, press Stop ( ).

Serial Wrap test

The serial wrap tests are used to check the operation of the serial port hardware using a wrap plug. Use Serial 1 Wrap if a serial port is available through PCI slot 1 and Serial 2 Wrap if the serial port is available through PCI slot 2. To perform the Serial Wrap tests:

1. Disconnect the serial interface cable, and install the serial wrap plug. 2. Select Serial 1 Wrap or Serial 2 Wrap from HARDWARE TESTS.
The power indicator blinks green indicating the test is in progress. The test runs continuously until a maximum number of tests is reached. P:###### F:####

P:###### represents the number of times the memory test has passed and finished successfully.
Initially 000000 displays with the maximum pass count being 999,999.

F:##### represents the number of times the memory test has failed and finished with errors. Initially
0000 displays with the maximum fail count being 999,999. Initially only four digits appear, but additional digits appear as needed. Each time the test finishes, the screen updates. If the test passes, the pass counter increases by 1, however if the test fails, a message displays for approximately three seconds. Once the maximum count is reached, the test stops. The power indicator goes on solid, and the final results display. To stop the test before completion, press Stop ( ).The message Serial Wrap x Test Canceled displays, and the printer returns to the HARDWARE TESTS menu.

3-10 Service Manual

DUPLEX TESTS
Quick Test (duplex)
This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page. You can run one duplexed page (Single), or continue printing duplexed pages (Continuous) until Stop ( Margin (duplex) on page 3-11. ) is pressed. For information about changing the margin, see Top

Note: Before you set the duplex top margin, be sure to set the registration. See Registration (printer) on page 3-5. The paper you choose to print the page on should be either Letter or A4. To run the Quick Test (duplex):

1. Touch 2. Touch

to select Quick Test from DUPLEX TESTS. to select Single or Continuous.

The single Duplex Quick test cannot be canceled. The printer attempts to print the Quick Test Page from the default paper source. If the default paper
source only supports envelopes, then the page is printed from Tray 1.

Check the Quick Test Page for the correct offset between the placement of the first scan line on the
front and back side of a duplexed sheet. The single test stops automatically when a single duplex sheet is printed, and the continuous test continues until you press Stop (

).

Top Margin (duplex)

This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin. See Registration (printer) on page 3-5. To set the Top Margin (duplex):

1. Print the Quick Test (duplex): a. Touch to select Quick Test from DUPLEX TESTS. b. Select Single. c. Hold the page to the light to see the whether the top margin of the backside aligns with the top margin
of the frontside.

2. Select Top Margin from DUPLEX TESTS. 3. Use the arrows to increase or decrease the current setting displayed on the touchscreen to select the
margin setting: [setting's current value] .

Each increment shifts the duplex top margin by 1/100 of an inch. The Top Margin (duplex) range is -20 to +20, and the default value is 0. An increase moves the top margin down and widens the top margin. A decrease moves the top
margin upward and narrows the top margin.

4. Touch Submit. 5. Print the Quick Test (duplex) again to verify the adjustment. Repeat if necessary.

Diagnostic aids

3-11

Sensor Test (duplex)

This test is used to determine whether or not the duplex sensors and switches are working correctly. The test allows you to actuate the duplex input sensor located in the back part of the duplex unit and the duplex exit sensor located in the return paper path.

1. Select Sensor Test from DUPLEX TESTS.

The message Sensor Test Testing displays.

2. Manually actuate each of the duplex sensors. When the sensor/switch is closed, CL (closed) displays, and
when the sensor/switch is open, OP (open) displays.

Duplex input sensor Duplex exit sensor 3. Press Stop ( ) to exit the test.

Motor Test (duplex)

This test lets you test the duplex option paper feed drive system, and verify that the power and velocity values are acceptable. The duplex runs the DC motor at high speed and low speed, taking an average of the power (PWM) required for each speed and calculating the KE value. To run the Motor Test (duplex):

1. Select Motor Test from DUPLEX TESTS.

The power indicator light blinks, and the message Motor Test Testing displays.

2. When the motor stops, the results are displayed.

DUPLEX MOTOR AA BB CC DD EE FF

AA00 indicates success, and any other value indicates failure. BBaverage PWM for the high speed portion of the test. The results should be in the range of 20
through 3F inclusively (hex)

CCaverage PWM for the low speed portion of the test The results should be in the range of 3A
through 5D inclusively (hex)

DDminimum PWM for the low speed portion of the test. The results should be in the range of 11
through 1F inclusively (hex)

Ignore bytes EE and FF.

If the test fails, remove the drive belt from the duplex DC motor, and run the motor test again. For the duplex DC motor to pass the test, the following results must display:

AA = 00 BB = in the range of 29 through 3E inclusively (hex) CC = in the range of 35 through 51 inclusively (hex) DD = in the range of 0C through 13 inclusively (hex)

For the duplex drive system to pass the test, the following results must display:

AA = 00 BB = in the range of 29 through 3F inclusively (hex) CC = in the range of 3A through 5D inclusively (hex) DD = in the range of 11 through 1F inclusively (hex) ) to exit the test.

3. Touch Back or press Stop ( 3-12 Service Manual

Duplex Feed 1
This test feeds a blank sheet of paper to the duplex paper stop position 1. This test can be run using any of the supported paper sizes. To run the Duplex Feed 1 Test:

1. Touch

to select Duplex Feed 1 from DUPLEX TESTS.

The power indicator blinks while the paper is feeding, and the message Duplex Feed 1 Feeding displays. The message Duplex Feed 1 Clear Paper displays when the paper reaches paper stop position 1, and the power indicator turns on solid.

2. Remove the media from the duplex unit, and clear the message on the operator panel by touching Back or
pressing Stop ( ).

Duplex Feed 2
This test feeds a blank sheet of paper to the duplex paper stop position 2. This test can be run using any of the supported paper sizes. To run the Duplex Feed 2 Test:

1. Touch

to select Duplex Feed 2 from DUPLEX TESTS.

The power indicator blinks while the paper is feeding, and the message Duplex Feed 2 Feeding displays. The message Duplex Feed 2 Clear Paper displays when the paper reaches the duplex paper stop position 2, and the power indicator turns on solid.

2. Remove the media from the duplex unit, and clear the message on the operator panel by touching Back or
pressing Stop ( ).

INPUT TRAY TESTS

Feed Tests (input tray)
This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder. The paper is placed in the output bin. To run the Input Tray Feed Tests:

1. Touch 2. Touch 3. Touch

to select Feed Tests from INPUT TRAY TESTS.

to select the input source from the sources displayed on the Feed Tests menu. All installed sources are listed. to select either Single or Continuous.

Singlefeeds one sheet of media from the selected source. Continuousmedia continues feeding from the selected source until Stop ( ) is pressed.

Diagnostic aids

3-13

Sensor Test (input tray)

This test is used to determine if the input tray sensors are working correctly. To run the Input Tray Sensor Test:

1. Touch 2. Touch

to select the Sensor Test from INPUT TRAY TESTS.

to select the input source from the sources displayed on the Sensor Test menu. All installed sources are listed.

3. Select the sensor to test. Various sources have different combinations of sensors. See the table below:
Tray sensor support by source
Source Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 Multipurpose tray Envelope feeder [sensor selected]=Open displays. Empty (Input tray empty sensor) Low (Input tray paper low sensor) passThru (Input tray pass thru sensor)

EmptyInput tray empty sensor LowInput tray paper low sensor passThruInput tray pass thru sensor 4. Once this message displays, the servicer can manually actuate each sensor. The tray empty sensor can be
actuated by hand, however a sheet of paper can be used to cover the pass thru sensor. When the sensor is closed, Closed displays; when the sensor is open, Open displays.

5. Press Stop (

) to exit the test.

OUTPUT BIN TESTS

Feed Tests (output bins)
Use these tests to verify that media can be fed to a the standard output bin. No information is printed on the media fed to the output bin because the printhead is not engaged during this test. These tests can use any media size or envelope supported by the printer. To run the Feed Tests for the output bins:

1. Touch 2. Touch

to select Feed Tests from the OUTPUT BIN TESTS. to select the output bin you want the paper to exit into.

3-14 Service Manual

3. Touch

to select either Single or Continuous.

Singlefeeds one sheet of media from the selected source. Continuousmedia continues feeding from the selected source until Stop (
Touch Back to return to OUTPUT BIN TESTS.

) is pressed.

Sensor Test (standard output bin)

This test is used to verify if the standard bin sensor is working correctly. To run the Sensor Test for the standard bin:

1. Touch 2. Touch

to select Sensor Test from OUTPUT BIN TESTS. to select Standard Bin from Sensor Tests.

3. Manually actuate the bin sensor by moving the flag in and out of the sensor and the display changes.
The following screen is displayed: Bin Empty: empty or Bin Empty: full.

4. Press Stop (

) to exit the test.

BASE SENSOR TEST

This test is used to determine if the sensors located inside the printer are working correctly. To run the Base Sensor Test:

1. Select BASE SENSOR TEST from the DIAGNOSTICS menu.

The following sensors are listed:

ExitExit sensor Front DoorFront door sensor InputInput sensor NarrowMediaOutput (exit) sensor Toner LevelToner level sensor (remove the cartridge and replace to actuate the sensor)

2. Manually actuate the sensors to verify that each sensor switches from Open to Closed. 3. Press Stop (
) to exit the test.

Diagnostic aids

3-15

DEVICE TESTS
Quick Disk Test
This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the block is good, the saved data is written back to the disk. To run the Quick Disk Test:

1. Touch

to select Quick Disk Test from DEVICE TESTS.

The power indicator blinks while the test is in progress, and quick Disk Test Testing displays.

Quick Disk Test/Test Passed message displays if the test passes, and the power indicator
turns on solid.

Quick Disk Test/Test Failed message displays if the test failed, and the power indicator turns
on solid.

2. Press Stop ( Disk Test/Clean

) to return to the Device Tests menu.

Warning: This test destroys all data on the disk and should not be attempted on a good disk. Also note that this test may run approximately 1 hours depending on the disk size. To run the Disk Test/Clean Test:

1. Touch

to select Disk Test/Clean from the Device Tests menu.

Contents will be lost. Continue? message displays to warn the user that all contents on the disk will be lost.

2. Touch Yes to continue and No to exit.

If Yes is selected, the following screen displays and updates periodically indicating the percentage of test completed. Formatting Disk 0% 1/1 DO NOT POWER OFF The power indicator blinks during the test. Note: The test can NOT be canceled.

3. Once the test is complete, the power indicator turns on solid, and either the message Disk Test/Clean
Test Passed or Disk Test/Clean Failed appears. If the message indicates failure, the disk is unusable.

3-16 Service Manual

Flash Test
This test verifies the functioning of the flash device by writing and reading data on the flash to test the flash. Warning: This test destroys all data on the flash because the flash is unformatted at the end of the test. To reformat the flash, the servicer or the user must use FORMAT FLASH from the UTILITIES MENU. To run the Flash Test:

1. Touch

to select Flash Test from DEVICE TESTS.

The message Contents will be lost. Continue? displays to warn the user that all contents on the flash device will be lost.

2. To exit the test immediately and return to the Device Tests menu, touch No. To continue, touch Yes.
The power indicator blinks while the test is running, and the message Flash Test Testing displays. Once the test is complete, the power indicator turns on solid, and either the message Flash Test Test Passed or Flash Test Test Failed displays.

3. Touch Back or press Stop (

) to return to DEVICE TESTS.

PRINTER SETUP
Models X644e/X646e
PRINTER SETUP Defaults Printed Page Count Permanent Page Count Serial Number Envelope Enhance Engine Setting 1
xxxxxxx

Model X642e PRINTER SETUP

US 127 127

Defaults U.S. Printed Page Count 127 Perm Page Count 127 Serial Number xxxxxxx

Medium 0

Submit
Submit
Back

Back

The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to display these additional menus. Note: If you make changes, touch Submit to make the change effective.

Defaults
US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US factory defaults. The settings affected include paper size, envelope size, PCL symbol set, code pages, and units of measure. Warning: Changing this setting resets the printer to factory defaults, and data may be lost. It cannot be undone.

Diagnostic aids

3-17

Printed Page Count

The page count can only be viewed and cannot be changed. Touch Back to return to Diagnostics Menu.

Permanent Page Count

The permanent page count can only be viewed and cannot be changed. Touch Back to return to Diagnostics Menu.

Serial Number
The serial number can only be viewed and cannot be changed. Touch Back to return to Diagnostics Menu.

Envelope Enhance
This setting affects the level of the fuser solenoid. To set Envelope Enhance:

1. The current value is displayed:

[setting's current value] The values are Low, Medium, and High. The default is Medium.

2. Touch

or

to change the value.

Touch Back to return to Diagnostics Menu.

Engine Setting 1 through 4

Warning: Do not change these settings unless requested to do so by your next level of support.

Model Name
The model name can only be viewed and cannot be changed.

3-18 Service Manual

Configuration ID
The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The configuration IDs are originally set at the factory when the printer is manufactured, however, the servicer may need to reset 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 menu is in DIAGNOSTICS, Check Config ID displays.
To set the configuration ID:

1. Touch 2. Touch

to select PRINTER SETUP from the Diagnostics Menu. to select Configuration ID.

3. Touch the keyboard icon to display a keyboard with 1 through 0 and a through f. The current values for
Configuration ID 1 and Configuration ID 2 are displayed.

Use keys to type the numbers for the two configuration IDs. Use the left arrow to move over a digit from the right of the number toward the left. When the numbers are correct, touch Submit. If you have a question, touch the question mark icon. To exit without changing the numbers, touch Back.

Note: Be sure to touch Submit, or the number will not be changed. Submitting Selection displays, followed by the value for Configuration ID 1. Note: If Invalid ID appears, the entry is discarded, and the previous Configuration ID 1 is displayed on the screen. If the process is successful, Submitting Selection appears on the display, followed by the current value for Configuration ID 2.

4. Restart the printer. Edge to Edge

When this setting is On, the text and graphics are shifted to the physical edges of the paper for all margins. When the setting is Off, the normal margins are restored.

Parallel strobe adjustment (Par x Strobe Adj)

This setting adjusts the amount of time the strobe is sampled in order to determine if the valid data is available on the parallel port. The range of values are from -4 to 6, and the default is 0 for Par S Strobe Adj, Par 1 Strobe Adj, and Par 2 Strobe Adj. After adjustment of 1 increment, the strobe samples 50 ns longer.

Diagnostic aids

3-19

EP SETUP
Models X644e/X646e
EP SETUP
EP Defaults

Model X642e EP SETUP

EP Defaults
Normal 127

Fuser Temp Fuser Page Count Warm Up Time Transfer Print Contrast

Fuser Temp Normal Fuser Page Count 127

Medium Medium

Warm Up Time 0

Submit
Submit
Back

Back

The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to display these additional menus. Note: If you make changes, touch Submit to make the change effective.

EP Defaults
This setting is used to restore each printer setting listed in EP SETUP to its factory default value. Sometimes this is used to help correct print quality problems. To restore EP Defaults:

1. Touch 2. Touch

to select EP Defaults from EP SETUP. to select Do Not

to select Restore to reset the values to the factory settings, and touch Restore to exit without changing the settings.

Touch Back to exit without changing the settings.

Fuser Temperature (Fuser Temp)

This adjustment can be used to help solve some customer problems with paper curl on low grade papers and problems with letterheads on some types of media. The fuser temperature can be adjusted to: Normal, Lower, Lowest. The default is Normal. Touch Back to return to Diagnostics Menu.

Fuser Page Count

The fuser page count can only be viewed and cannot be changed. Touch Back to return to Diagnostics Menu.

Warm Up Time
You can change the amount of time the printer warms up before allowing pages to print by changing this setting from 0 to 5. The factory sets the warm up at 0 or no warm up time. This time period lets the backup roll heat up and helps reduce curl in some environments.

3-20 Service Manual

Touch Back to return to Diagnostics Menu.

Transfer
The transfer can be adjusted to Low, Medium, or High. The default setting is Medium. Touch Back to return to Diagnostics Menu.

Print Contrast
The print contrast setting controls the developer voltage offset. The print contrast can be adjusted to Low, Medium, or High. The default setting is Medium. Touch Back to return to Diagnostics Menu.

Charge Roll
The charge roll can be adjusted to Low, Medium, or High. The default setting is Medium. Touch Back to return to Diagnostics Menu.

Gap Adjust
The setting adjusts the minimum gap between sheets. Increasing this value may reduce curl of some printed media and eliminate some output bin stacking problems. However, increasing this value also results in slower overall performance, measured in pages per minute. The range of values is 0 to 255, and the default value is 0. Touch Back to return to Diagnostics Menu.

EVENT LOG
Display Log
The event log provides a history of printer errors. It contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1, and the oldest error displays in position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is discarded. Identical errors in consecutive positions in the log are entered, so there may be repetitions. All 2xx and 9xx error messages are stored in the event log. To view the event log:

1. Touch

to select Display Log from EVENT LOG. to display additional information, if available.

Up to three error codes display at a time. Touch

2. Touch Back to return to the EVENT LOG menu.

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Print Log
Additional diagnostic information is available when you print the event log from Diagnostics Menu rather than Configuration Menu. The Event Log printed from Diagnostics Menu includes:

Detailed printer information, including code versions Time and date stamps Page counts for most errors Additional debug information in some cases

The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis. To print the event log: Touch to select Print Log from EVENT LOG.

Clear Log
Use Clear Log to remove the current information in the Event Log. This affects both the viewed log and the printed log information.

1. Touch 2. Touch

to select Clear Log from the Event Log menu.

to select Yes to clear the Event Log, or touch to select NO to exit the Clear Log menu. If YES is selected, Deleting EVENT LOG displays on the screen.

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SCANNER TESTS
ASIC Test
A pattern appears and ASIC Test Passed displays. If xxxxxx displays, the test was unsuccessful. Press Stop (

) to return to the SCANNER TESTS menu.

Feed Test
To run the Scanner Feed test:

1. Touch

to select Feed Test from the SCANNER TESTS menu. [setting's current value] . Use the arrows to select from

2. The panel displays the setting's current value

Letter, Legal, or A4.

3. Touch START to begin.

Feed Test Testing displays. Press 4 to exit the test.

4. Touch Back to return to the Diagnostics Menu. Scanner Manual Registration

Note: Do not change these settings unless requested to do so by your next level of support

Sensor Tests
The following tests are available: ADF cover Open ADF Exit Sensor ADF Interval ADF Jam Removal ADF Paper Present FB Cover Open Home Sensor SCAN_QRY_PAPER_SIZE_ADF_LONG SCAN_QRY_PAPER_SIZE_ADF_WIDTH1 SCAN_QRY_PAPER_SIZE_ADF_WIDTH2 SCAN_QRY_PAPER_SIZE_ADF_WIDTH3 SCAN_QRY_PAPER_SIZE_FB_LONG SCAN_QRY_PAPER_SIZE_FB_MEDIUM SCAN_QRY_PAPER_SIZE_FB_SHORT SCAN_SENSOR_FIRST_SCAN_BIT SCAN_SENSOR_SECOND_SCAN_BIT

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Configuration menu (CONFIG MENU)

Entering Configuration Menu
1. Turn off the printer. 2. Press and hold 2 and 6 buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds.

Available menus
Note: Some menus are not available, depending on the configuration of the printer. Maintenance Page Counter Reset Maintenance Counter Print Quality Pages SIZE SENSING Panel Menus PPDS Emulation Factory Defaults Energy Conserve Min Copy Memory Format Fax Storage ADF Edge Erase FB Edge Erase Automatic Scanner Registration EVENT LOG (print log only) Paper Prompts Env Prompts Jobs On Disk Disk Encryption Wipe Disk Font Sharpening Require Standby LES App[lications Key Repeat Initial Delay Key Repeat Rate Wiper Message See Maintenance Page Count on page 3-25 See Reset Maintenance Counter on page 3-25 See Print Quality Pages on page 3-26 See SIZE SENSING on page 3-26 See Panel Menus on page 3-27 See PPDS Emulation on page 3-27 See Factory Defaults on page 3-28 See Energy Conserve on page 3-28 See Min Copy Memory on page 3-29 See Format Fax Storage on page 3-29 See ADF Edge Erase on page 3-29 See FB Edge Erase on page 3-30 See Automatic Scanner Registration on page 3-30 See EVENT LOG on page 3-31 See Paper Prompts on page 3-31 See Envelope Prompts on page 3-32 See Jobs On Disk on page 3-32 See Disk Encryption on page 3-32 See Wipe Disk on page 3-33 See Font Sharpening on page 3-34 See Require Standby on page 3-34 See LES Applications on page 3-34 See Key Repeat Initial Delay on page 3-35 See Key Repeat Rate on page 3-35 See Wiper Message on page 3-35

Touch Exit Config Menu to exit the Configuration Menu and Resetting the Printer displays. The printer performs a POR, and the printer returns to normal mode.
Exit
Config Menu

Exit Config Menu

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Maintenance Page Count

The current value for the maintenance page counter is displayed. This counter tracks printer usage. A print job containing a single page increments the counter by one and a duplex page by two. At 300,000, the customer is reminded that the printer requires scheduled maintenance. This counter is reset by the servicer after a 80 Scheduled Maintenance message displays and a maintenance kit is installed. See Maintenance kit on page 6-1 for the part number. To view the maintenance page count touch value is displayed and cannot be changed. to select Maint Cnt Value from the Configuration Menu. The

Touch Back to return to the main Configuration Menu.

Reset Maintenance Counter

After scheduled maintenance, the servicer needs to reset the page counter. To reset the maintenance page count to zero:

1. Touch

to select Reset Maintenance Counter from the Configuration Menu.

2. Touch Yes to reset the counter or touch No to exit without resetting the counter.

Reset Maintenance Counter

Yes

No

The message Reset Maint Cnt=Reset displays momentarily. When the reset operation is complete, the menu returns to the main Configuration Menu.

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Print Quality Pages

The print quality test pages can be printed from either the Diagnostics Menu or Configuration Menu (CONFIG MENU). When printed from the Diagnostics Menu, additional information is included, and the print cartridge lockout is bypassed. See Print Quality Pages on page 3-26. Additional configuration information may be included on the print quality pages which is not included on the print menu page. To print the Print Quality Test Pages, touch to select Prt Quality Pgs from Configuration Menu. The message Printing Quality Test Pages is displayed. The following is printed:

Settings from EP SETUP from the Diagnostics Menu:

Fuser temperature, warm up time, transfer, print contrast, and charge roll settings.

Contents of the EVENT LOG from the Diagnostics Menu. Printer configuration information:
Printer serial number, controller code level, engine code level, operator panel code level, smart option code levels, font versions, and so on. Values for the QUALITY MENU settings used to print the pages. The print quality test consists of four pages. Page one contains a mixture of graphics and text. Pages two and three only contain graphics. Page four is blank. If duplex is turned on, the pages are duplexed. The Print Quality Test pages are printed in English and must always be printed on letter, legal, or A4 paper.

SIZE SENSING
This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing. Paper source Tray 1 (integrated) Multipurpose feeder 250-sheet drawer 500-sheet drawer 2000-sheet drawer 250-sheet duplex 500-sheet duplex Envelope feeder When the setting is Auto, every input option equipped with size sensing hardware automatically registers what size media it contains. When the setting is Off, the media size detected by hardware is ignored. The media size can be set by the operator panel or the data stream. Size sensing

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To change the size sensing setting:

1. Touch
row. Touch

to select SIZE SENSING from the Configuration Menu. [setting's current value] below the header

2. The panel displays the setting's name in the header and

or

to change the setting. The selections are Auto and Off.

3. Touch Submit to save your change.

Touch Back to exit without changing the value.

Panel Menus
To change the Panel Menus setting:

1. Touch
row. Touch

to select Panel Menus from the Configuration Menu. [setting's current value] below the header

2. The panel displays the setting's name in the header and

or

to change the setting. The selections are Disable and Enable. The default is Enable.

3. Touch Submit to save your change.

Touch Back to exit without changing the value.

PPDS Emulation
This menu item allows the user to enable or disable PPDS emulation data stream. When this setting is enabled, the following settings are also changed:

SmartSwitch settings for each port are turned off. The printer language is changed to PPDS Emulation.
Users can still switch languages on the operator panel and through the PJL data stream. To change the PPDS Emulation setting:

1. Touch

to select PPDS Emulation from the Configuration Menu. [setting's current value] below the header

2. The panel displays the setting's name in the header and

row. Touch Deactivate. or

to change the setting. The selections are Activate and Deactivate. The default is

3. Touch Submit to save your change.

Touch Back to exit without changing the value.

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Factory Defaults
This setting enables a user to restore all the printer settings to the original factory settings. Selections are Restore Base, Restore Network, or Restore LES. Restore LES enables you to remove all Lexmark Embedded Solutions applications (LES). Network does not appear unless you have a network printer. The following settings are not changed:

Display language Settings in the NETWORK/PORTS MENU group.

To reset factory defaults:

1. Touch 2. Touch

to select Factory Defaults from the Configuration Menu. to select either Restore Base, Restore Network, or Restore LES.

Note: There is no confirmation, and selecting one of these settings immediately takes effect. The MFP restarts and returns to Ready state. Restoring Factory Defaults and then Resetting the Device are displayed.
Factory Defaults
Restore Base

Restore Network

Restore LES

Back

Energy Conserve
This menu controls what values appear on the Power Saver menu. If Off is selected in Energy Conserve menu, then Disabled appears in the Power Saver menu, and Power Saver can be turned off. If On is set in Energy Conserve, the Power Saver feature cannot be disabled.

1. Touch
row. Touch

to select Energy Conserve from the Configuration Menu. [setting's current value] below the header

2. The panel displays the setting's name in the header and

or

to change the setting. The selections are On and Off. The default is On.

3. Touch Submit to save your change.

Touch Back to exit without changing the value.

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Min Copy Memory

1. Touch
to select Min Copy Memory from the Configuration Menu. [setting's current value] below the header

The panel displays the setting's name in the header and row.

2. Touch

or

to change the setting.

For example, the values may be 25 MB, 35 MB, 50 MB, and 100 MB. The default is 25 MB. Values will only be displayed if the amount of installed DRAM is at least twice the amount of the value, that is, at least 200 MB of installed DRAM is required to display the 100 MB selection.

3. Touch Submit to save your change.

Touch Back to exit without changing the value.

Format Fax Storage

This setting enables you to format the non-volatile storage used for storing faxes. To change this setting, touch to select Format Fax Storage from the Configuration Menu. Formatting Fax Flash DO NOT POWER OFF appears on the LCD while the format operation is active. Note: If an advanced password has been established, you must enter this password in order to change the setting.

ADF Edge Erase

The ADF Edge Erase and FB Edge Erase settings specify, in millimeters, the size of a border around the scanned image that will be erased. For copies, the printed page will have 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. To change this setting:

1. Touch

to select ADF Edge Erase from the Configuration Menu. [setting's current value] below the header

The panel displays the setting's name in the header and row.

2. Touch

to increase the value or

to decrease the value.

The values are 0 through 6. The default is 3.

3. Touch Submit to save the change.

Touch Back to cancel and return to the Configuration Menu.

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FB Edge Erase
The ADF Edge Erase and FB Edge Erase settings specify, in millimeters, the size of a border around the scanned image that will be erased. For copies, the printed page will have 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. To change this setting:

1. Touch

to select FB Edge Erase from the Configuration Menu. [setting's current value] below the header

The panel displays the setting's name in the header and row.

2. Touch

to increase the value or

to decrease the value.

The values are 0 through 6. The default is 3.

3. Touch Submit to save the change.

Touch Back to cancel and return to the Configuration Menu.

Automatic Scanner Registration

To perform the Automatic Scanner Registration:

1. Obtain two pieces of colored paper (A4 or letter) for the automatic registration. Use a light blue sheet or
other solid color paper. Note: Always store the colored sheets so they do not become creased or torn. The sheets can be used if you need to run Automatic Scanner Registration at another time.

2. Scroll through the menus using the down arrow, and select Automatic Scanner Registration from the
Configuration Menu.

Please place a piece of dark colored paper on the Flatbed and in the ADF

Start

Back

3. Place a colored piece of paper in the ADF, making sure the edge guides are properly adjusted. Place
another piece of paper (A4 or letter) on the flatbed. Touch Start.

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4. The touchscreen displays DO NOT POWER OFF Scanner Registration. When complete, a screen
similar to the following should appear:

Scanner registration successfully completed

Continue

5. Touch Continue.
Note: If the Automatic Scanner Registration displays a failure, repeat the process making sure the paper is aligned as correctly as possible. If the process fails again, contact the next level of support.

EVENT LOG
The event log provides a history of printer errors. The event log can only be printed in CONFIG MENU. Additional options are available in DIAGNOSTICS. See EVENT LOG on page 3-21. To print the event log:

1. Touch 2. Touch

to select Event Log from Configuration Menu. to print the log. Printing Event Log. displays on the touchscreen.

3. Touch Back to return to EVENT LOG.

Note: An event log printed from the CONFIG MENU will not contain debug information or secondary codes for 900 service errors. However, the event log printed from DIAGNOSTICS mode does include this information.

Paper Prompts
When a tray is out of the indicated paper size, a prompt is sent to the user to load paper in a tray. This setting controls the tray the user is directed to fill.

1. Touch

to select Paper Prompts from the Configuration Menu. [setting's current value] below the header

The panel displays the setting's name in the header and row.

2. Touch

or

to change the value.

The values are Auto (default), MP Feeder, and Manual Paper.

3. Touch Submit to save the change.

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Envelope Prompts
This setting controls the tray the user is directed to refill when a specific envelope size is out. The selections are Auto (default), MP Feeder, and Manual Env.

1. Touch

to select Envelope Prompts from the Configuration Menu. [setting's current value] below the header

The panel displays the setting's name in the header and row.

2. Touch

or

to change the value.

The values are Auto (default), MP Feeder, and Manual Envelope.

3. Touch Submit to save the change.

Jobs On Disk
Model X646e only. If the hard disk is installed, Jobs On Disk allows the user to delete buffered jobs saved on the disk. The values are Delete and Do Not Delete. To delete jobs saved on the disk:

1. Touch 2. Touch 3. Touch

to select Jobs On Disk from the Configuration Menu. to select Delete to decrease the setting's value. or to change the value.

Touch Back to cancel and return to the Configuration Menu.

Disk Encryption
Model 500S only. If a hard disk is installed, Disk Encryption selects whether the data on the disk is encrypted or not. The values are Disable and Enable. This setting determines if the printer encrypts the information that it writes to the hard disk. The values are Disable and Enable. Warning: If the value is changed from Enable to Disable or from Disable to Enable, then the printer completely formats the hard disk. All information on the disk will be unrecoverable. To change this setting:

1. Touch

to select Disk Encryption from the Configuration Menu.

Note: If an advanced password has been established, you must enter this password in order to change the setting. If no advanced password exists, you can establish one by using the keyboard that appears on the LCD.

2. Touch

next to either Enable or Disable.

If you remove an encrypted disk from a device and then try to install another disk, Disk Corrupted. Reformat? appears on the LCD. You can format the newly installed disk or remove it from the device.

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3. Contents will be lost. Continue? appears on the touchscreen. Touch No to cancel or Yes to
proceed. If you select Yes, the printer performs the selected action on the hard disk. The following graphic appears when the encryption process is selected:

The panel provides many progress indicators during the two-stage process.

1/2 indicates that the process is currently in the first stage. 0% indicates the progress of the current stage of the process. The progress bar indicates the overall completion of the entire process by filling in throughout each
separate stage. When the first stage of either process completes, the printer displays either of the following graphics depending on the process selected and then begins the second stage of the process:

The entire process is complete when the progress bar appears completely shaded and the percentage indicator shows 100%. After completion, the panel returns to Disk Encryption.

Wipe Disk
This setting provides you with a tool for erasing the contents of a disk. Warning: Wipe Disk removes a disk's data in such a way that it cannot be recovered. To change this setting:

1. Touch

to select Wipe Disk from Configuration Menu.

Note: If an advanced password has been established, you must enter this password in order to change the setting. If no advanced password exists, you can establish one by using the keyboard that appears on the LCD.

2. Touch

to select Wipe disk now.

Contents will be lost. Continue? appears on the touchscreen.

3. Touch Back to return to EVENT LOG. 4. Touch Yes to continue, or touch No to exit.

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Font Sharpening
This setting allows a user to set a text point size below which the high frequency screens are used when printing font data. For example, at the default 24, all text in font sizes 24 and less will use the high frequency screens. The values for this setting range from 0 to 150, and the default value is 24. This setting affects PostScript, PCL, and XL. To change this setting:

1. Touch 2. Touch

to select Font Sharpening from the Configuration Menu. to increase the value or to decrease the value.

3. Touch Back to cancel and return to the Configuration Menu. 4. Touch Submit to save the change.
This function is not supported when the device generates output at 600 dpi resolution.

Require Standby
This setting determines if the Standby Mode is On or Off. The default is On. If Standby Mode is on, the printer begins functioning in Standby Mode when it remains idle for an amount of time. The Standby Mode enables the printer:

To consume less energy than when operating in normal mode but not as little as when operating in Power
Saver To return to the Ready state more quickly than when operating in Power Saver

To change this setting:

1. Touch

to select Require Standby from the Configuration Menu.

2. Touch Back to cancel and return to the Configuration Menu. 3. Touch Submit to save the change.

LES Applications
This disables all installed OEM Embedded Solution applications. The default is Enabled. To change this setting:

1. Touch

to select LES Applications from the Configuration Menu.

Note: If an advanced password has been established, you must enter this password in order to change the setting. If no advanced password exists, you can establish one by using the keyboard that appears on the LCD.

2. Touch Back to cancel and return to the Configuration Menu. 3. Touch Submit to save the change.

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Key Repeat Initial Delay

When a key is touched repeatedly, this is the delay before the key begins repeating. The delay ranges from 0.25 seconds to 5 seconds. The default is 1 second. Values are given in increments of 0.25 seconds. To change this setting:

1. Touch 2. Touch

to select Key Repeat Initial Delay from the Configuration Menu. to increase the value or to decrease the value.

3. Touch Submit to save the change.

Touch Back to cancel and return to the Configuration Menu.

Key Repeat Rate

This is the number of times per second that a repeating key will repeat. The range is 1100, with a default of 15 times per second. To change this setting:

1. Touch 2. Touch

to select Key Repeat Initial Delay from the Configuration Menu. to increase the value or to decrease the value.

3. Touch Submit to save the change.

Touch Back to cancel and return to the Configuration Menu.

Wiper Message
To change this setting:

1. Touch 2. Touch

to select Wiper Message from the Configuration Menu. or to change the value. The values are On (default) and Off.

3. Touch Submit to save the change.

Touch Back to cancel and return to the Configuration Menu.

Exit Configuration Menu

Touch Exit Config Menu to exit the Diagnostics Menu and Resetting the Printer displays. The printer performs a POR, and the printer returns to normal mode.
Exit
Config Menu

Exit Config Menu

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Theory
Autocompensator operation
The autocompensator is a paper pick device that generates its own normal force. This force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary, therefore no special trays are needed for card stock or labels. The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm. This movement produces a downward force at the pick rolls. The friction between the pick roll and the paper produces a frictional locking condition. If the paper is physically held and not allowed to feed, then the motor stalls. Slippage between the roll and the paper is theoretically impossible. When the motor is energized, the pick rolls are driven down into the stack, increasing the normal force and drive force until the bending strength of the paper is overcome and the paper bends and moves up the dam. Once this critical threshold is achieved, the normal force remains at a level just high enough to reliably feed the paper. Rather than having a fixed spring force for feeding all weights of paper like the D-roll, this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness. High normal force is one of the most significant contributors to double feeding paper. The pick arm is counterbalanced by an extension spring located on the pick arm to reduce weight in the rest state. This spring is factory set to exert no more than ten to fifteen grams on the stack. This is as light as can be realistically set and always guarantee there is some force to start the autocompensating phenomena. This spring is not to be considered an adjustment for feeding problems unless it is obvious that the pick arm cannot fall all the way down to the bottom of the tray or has come loose. Poor gear efficiency can cause the arm to generate higher than normal forces. If the pick assembly is noisy, replacement may be required. The arm must pivot freely through its full range of motion. On 500-sheet trays, there are wrap springs located on the pivot arbors of the arm. These springs help prevent the arm from bouncing. If the arm appears to be binding or sticky near the bottom of the tray, these springs may be the problem. Reducing the tension on the counterbalance spring may be used as a temporary fix to get additional weight at the bottom, until the pick assembly can be replaced. However, the counterbalance spring is not to be considered an adjustment for feeding problems.

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Autoconnect system, paper tray options, envelope feederelectrical

Autoconnect cabling and connectors
The printer options make electrical connection automatically, requiring no external cables when the option is mechanically installed under the printer. Communication between the option and the printer stops when you remove an option. The printer no longer recognizes the option and deletes associated messages. Each installed option below the printer provides an electrical autoconnect to the option attached below it. We do not recommend to attach or Hot Plug any options with the printer power turned on.

Duplex Option
The duplex option interface is a six pin autoconnector that provides a +24 V dc, +24 V dc return, serial interface transmit signal, serial interface receive signal, and two ground pins. The duplex option receives the +24 V dc from the printer for the duplex motors and also converts the voltage to +5 V dc for duplex electronics. Duplex chassis grounding is provided from the printer to the duplex option through a ground spring attached to the frame and base of the printer. The ground connection is automatically made when the option is installed below the printer. The paper input sensor is located in the rear of the duplex option under the input paper guide. The paper exit sensor is located on the left frame assembly.

Option microcode
The options are Smart Options or options that have a system board. The option system board has a microprocessor that controls the option mechanism. A software architecture is provided that controls the option and communicates information such as paper path status, sensor status, motor status, and so on to the printer.

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Paper feed jams

By carefully selecting print media and loading it properly, you should be able to avoid most paper jams. For more information on avoiding paper jams, see Avoiding jams on page 1-16. If jams do occur, follow the steps outlined in this section. To resolve the paper jam messages, you must clear the entire paper path, and then touch Continue to clear the message and resume printing. The MFP prints a new copy of the page that jammed if Jam Recovery is set to On or Auto; however, the Auto setting does not guarantee the page will print.

Identifying jams
If the MFP jams, the appropriate jam message will be displayed on the touch screen Print status message bar.

Copy

Fax

E-mail

FTP

Status/ Supplies

200.01 Paper jam, [x] pages jammed. Leave paper in bin.

Menus

See the diagram on Access doors and trays on page 3-39 for an overview of the paper path and areas where jams may occur. The path varies depending on the MFP paper sources.

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Access doors and trays

The following illustration shows the path that print media travels through the MFP. The path varies depending on the input source (trays, multipurpose feeder, envelope feeder) you are using. The numbers in following the illustration indicate the numbers that can appear on the operator panel and designate the general area of a paper jam.

Doors and trays

CAUTION

Path and locations

Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet drawer. Certain other configurations also must have a printer stand or printer base.

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Understanding jam messages

The following table lists the jam messages that can occur and the action necessary to clear the message. The jam message indicates the area where the jam occurred. However, it is best to clear the entire paper path to ensure you have cleared all possible jams. Message 200 and 201 Paper Jam Remove Cartridge 202 Paper Jam Open Rear Door 23x Paper Jam Open Duplex Rear Door 250 Paper Jam Check MP Feeder 260 Paper Jam Check Env Feeder 290, 291, 292, and 294 Scanner Jams What to do* Open the bottom then top front covers, remove the print cartridge, and then remove the jam. Open the rear door on the MFP, and remove the jam. Remove the duplex tray from the duplex unit, raise the duplex deflector, and remove the jam. Open the rear duplex door, and remove the jam. Remove all media from the multipurpose feeder, flex and stack the media, reload the multipurpose feeder, and adjust the guide. Lift the envelope weight, remove all envelopes, flex and stack the envelopes, reload the envelope feeder, and adjust the guide. Remove all original documents from the ADF. Open the ADF cover, and remove any jammed pages. Open the document cover, and remove any jammed pages. Open the lower exit guide, and remove any jammed pages.

Clearing jams
Although there are several places a jam can occur, clearing the paper path is fairly easy. Paper jams can occur in three areas: the front of the MFP, inside the MFP, and at the rear of the MFP. Jams in the front of the MFP occur in the input options or the duplex tray. Jams inside the MFP occur in two locations and require the removal of the print cartridge. Jams can also occur at the rear of the MFP or duplex unit. Note: The following clearing jam instructions may seem out of numerical sequence. However, they have been grouped to help you quickly clear the print path. To go to a specific jam, see Understanding jam messages on page 3-40.

250 Paper Jam Check MP Feeder 1. Remove the paper from the multipurpose feeder. 2. Flex, fan, and restack the media, and place it into the multipurpose feeder. 3. Load the print media. 4. Slide the side guide toward the inside of the tray until it lightly rests against the edge of the media.

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5. Touch Continue.

260 Paper Jam Check Env Feeder

The envelope feeder feeds envelopes from the bottom of the stack; the bottom envelope will be the one that is jammed.

1. Lift the envelope weight. 2. Remove all envelopes.

If the jammed envelope has entered the MFP and cannot be pulled out, remove the envelope feeder.

a. Lift the envelope feeder out of the MFP, and then set it aside. b. Remove the envelope from the MFP.
Note: If you cannot remove the envelope, the print cartridge will have to be removed. See 200 and 201 Paper Jam Remove Cartridge on page 3-46 for more information.

c. Reinstall the envelope feeder. Make sure it snaps into place. 3. Flex and stack the envelopes.

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4. Load the envelope feeder. 5. Adjust the guide. 6. Lower the envelope weight. 7. Touch Continue.

2 1

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23x and 24x jams

Paper jams in these areas can occur on the incline surface of a tray or across more than one tray. To clear these areas:

1. Open the MFP paper tray, and remove any jammed media.

2. Open the duplex tray.

To remove the media, pull up.

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3. Open any optional trays beginning at the top, and remove any jammed media.
Pull the print media either up or down. If it does not pull easily one way, try the other way.

CAUTION Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet drawer. Certain other configurations also must have a printer stand or printer base.

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4. If you have an optional 2000-sheet feeder, open the front door, press the elevator button to lower the tray,
remove the jam, and make sure the stack of print media is neat and aligned.

5. Touch Continue.

CAUTION Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet drawer. Certain other configurations also must have a printer stand or printer base.

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200 and 201 Paper Jam Remove Cartridge 1. Push the release latch, and lower the multipurpose feeder. 2. Push the release latch, and open the top front cover.
CAUTION The inside of the MFP may be hot. Allow the MFP to cool before touching any internal components.

3. Lift and pull the print cartridge out of the MFP.

Warning: Do not touch the photoconductor drum on the underside of the cartridge. Use the cartridge handle whenever you are holding the cartridge.

4. Place the print cartridge aside.

Note: Do not leave the cartridge exposed to light for extended periods.

1
Note: The print media may be covered with unfused toner, which can stain garments and skin.

5. Pull the print media up and toward you.

CAUTION Do not use any pointed objects to remove the paper. This could cause personal injury or damage to the MFP. Warning: If the print media does not move immediately when you pull, stop pulling. You need to access the print media from the MFP rear door.

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6. Align and reinstall the toner cartridge. 7. Close the top front cover. 8. Close the multipurpose feeder. 9. Touch Continue.

2
202 Paper Jam Open Rear Door 1. If the paper is exiting the MFP, pull the media straight out, and then touch Continue. Otherwise, continue
with step 2.

2. Open the MFP rear door.

CAUTION The inside of the MFP may be hot. Allow the MFP to cool before touching any internal components.

CAUTION Do not use any pointed objects to remove the paper. This could cause personal injury or damage to the MFP.

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3. Remove the jammed media. 4. Close the rear door. 5. Touch Continue.

23x Paper Jam Open Duplex Rear Door 1. Open the duplex rear door.

2. Remove the jammed media.

Depending on the media location, pull the media either up or down.

3. Close the duplex rear door. Make sure it snaps into place.

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4. Touch Continue.

Clearing ADF jams

290, 291, 292, and 294 Scanner Jams 1. Remove all original documents from the ADF. 2. Open the ADF top cover, and remove any jammed pages. 3. Open the ADF cover, and remove any jammed pages.

1 2 4 5 7 8 9 0 #
0 #

3 6
7 4

1 2 3 5 6 8 9

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4. Open the lower entrance guide, and remove any jammed pages.

5. Close the lower exit guide. 6. Close the ADF cover.

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4. Repair information
Warning: Read the following before handling electronic parts.

Handling ESD-sensitive parts

Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards:

Keep the ESD-sensitive part in its original shipping container (a special ESD bag) until you are ready to
install the part into the machine.

Make the least-possible movements with your body to prevent an increase of static electricity from clothing
fibers, carpets, and furniture.

Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges
any 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 are electrical grounds. They increase the risk of damage because they
make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.) Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install machine covers when you are not working on the machine, and do not put unprotected ESD-sensitive parts on a table. If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case). Be extra careful in working with ESD-sensitive parts when cold-weather heating is used, because low humidity increases static electricity.

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Adjustment procedures
Fuser solenoid adjustment
Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while installed in the MFP. Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature. The solenoid air gap for all models is 4.5 mm 0.1 mm.

Gap adjustment
The gap adjustment allows you to increase the minimum gap between sheets of paper as they are fed through the MFP. This adjustment reduces the MFP overall performance, such as pages per minute, but can help in reducing the amount of curl of some printed media, thus improving media stacking in the output bin.

1. 2. 3. 4.

Enter the Diagnostic Menu. Select EP SETUP from the Diagnostic Menu. Select Gap Adjust. The range of the GAP adjustment is 0 to 255. Adjust the gap setting by using arrows to select the value and press Submit. If GAP=0 displays, it indicates a factory setting to minimum gap. Select a value, and run several copies of the media that displays a curl problem. It may take several tries before improvement is noticed.

Note: This setting has no effect when duplexing.

Printhead assembly adjustmentprinter

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

1. 2. 3. 4. 5.

Turn off the MFP. Press and hold the 3 and 6 buttons simultaneously, and turn on the MFP. Release the buttons after 10 seconds. Select Registration from the menu. Select Quick Test Page. The test page should only be printed on letter or A4 paper from Tray 1. The Quick Test Page consists of alignment diamonds, horizontal lines that can be used for skew adjustment, page count setting, MFP serial number code levels, and print registration settings. the test page for equal distance from the top of the page. If necessary, adjust the left or right printhead mounting screws, and check the skew again by running another Quick Test Page. This procedure may take two or three attempts before you get satisfactory results.

6. Check the Quick Test Page for any sign of skew by checking the diamonds at the top left and top right of

7. When you have the correct adjustment, gently tighten the printhead mounting screws, being careful not to
move the printhead assembly.

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Paper alignment assembly adjustment

Do the alignment assembly adjustment whenever you replace the alignment assembly. Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw. When replacing the alignment assembly, it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one.

If you are replacing the alignment assembly, go to step A. If you are only adjusting the reference adjustment screw, go to step B. Step A
Print a copy of the Quick Test Page, and check the margin adjustments printed on the test page. These settings should be within the range specified in Registration (printer) on page 3-5. Do the reference adjustment if you are sure the margins are set correctly.

1. Loosen the locknut on the inside rear of the alignment assembly. 2. Remove the two screws holding the alignment assembly to the left side frame. 3. Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from
the MFP. It is not necessary to completely remove the screw.

4. Install the new alignment assembly. Turn the reference screw clockwise with a 7 mm nut driver or M3 Allen
wrench until it touches the back of the reference plate, and tighten the nut with a 5.5 mm wrench. The reference adjustment screw can be adjusted without loosening the nut. Turn the screw clockwise a few turns, and print a copy of the Quick Test Page as you check the diamonds on the left margin. Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want.

Step B
Print a copy of the Quick Test Page, and check the margin adjustments printed on the test page. These settings should be within the range specified in Registration (printer) on page 3-5. The reference screw can be adjusted without loosening the locknut. Turn the screw a few turns, and print a copy of the Quick Test Page as you check the diamonds on the left margin. Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want.

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Scanner registration
Perform the Automatic Scanner Registration when:

The ADF assembly, CCD, RIP card or SCU card is replaced. NVRAM is reset. The operator panel is replaced. Automatic Scanner Registration
Note: Before performing scanner registration, ensure MFP registration and alignment is properly set. See Registration (printer) on page 3-5 and Printhead assembly adjustmentprinter on page 4-2 for more information. Note: Always store the colored sheets so they do not become creased or torn. To perform the Automatic Scanner Registration:

1. Enter the Configuration menu: a. Turn off the printer. b. Press and hold the 2 and 6 buttons simultaneously. c. Turn on the printer. d. Release the buttons after 10 seconds. 2. Scroll through the menus using the down arrow, and select Automatic Scanner Registration from the
Configuration menu.

Please place a piece of dark colored paper on the Flatbed and in the ADF

Start

Back

3. Place a colored piece of paper in the ADF, making sure the edge guides are properly adjusted. Place
another piece of paper (A4 or letter) on the flatbed. Note: Use a light blue sheet of paper for the ADF registration. The best results were obtained using Cascade MP Colors Blue 20 lb. paper (Boise Cascade part P1-MP-2201-BE). A moderate density blue paper should work if this paper cannot be found.

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4. Touch Start.
The touchscreen displays DO NOT POWER OFF Scanner Registration. When complete, a screen similar to the following appears:

Scanner registration successfully completed

Continue

5. Touch Continue.
Note: After the registration test is complete, success or failure is indicated on the touchscreen. Note: If the Automatic Scanner Registration displays a failure, repeat the process making sure the paper is aligned as correctly as possible. If the process fails again, contact the next level of support.

6. Verify the results by running a copy of a quick test page created during MFP registration. See Print tests
on page 3-6 for more information.

Manual registration
Note: Manual registration should be performed only after automatic registration is performed. The primary purpose of manual registration is to fine-tune the automatic adjustments already made. Contact your next level of support for assistance in performing the Manual Scanner Registration.

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Removal procedures
CAUTION Remove the power cord from the MFP or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the MFP. CAUTION Use the handholds on the side of the MFP. Make sure your fingers are not under the MFP when you lift or set the MFP down. Note: Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.

Scanner ADF and flatbed removals

ADF front cover removal
1. Open the ADF top cover. 2. Remove the two screws (A).

3. Release the ADF front cover latch (B) on the right side under the scanner, and then release the latch (B) on
the left side.

4-6 Service Manual

ADF pick assembly removal

1. Grasp the pick assembly, and gently push the shaft to the right to free the left side.

ADF rear cover removal

1. Remove the two screws (A).

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2. Remove the screw (B) on the right side.

3. Remove the cable blocks (C) from the square notches. For model 500S, there are two cables and
notches and for model 450S, there is a single cable. Model 500S Model 450S

Replacement note: When replacing the ADF rear cover, be sure to align the cables (C) in the notches and press the square portions of the cables into the holes.

4-8 Service Manual

ADF top cover removal

1. 2. 3. 4.
Remove the ADF front cover. See ADF front cover removal on page 4-6. Remove the ADF rear cover. See ADF rear cover removal on page 4-7. Open the ADF top cover. Remove the shoulder screw (A) on the front.

5. Remove the shoulder screw (B) on the rear with a long shank screwdriver. Model 500S shown.

6. Remove the ADF top cover.

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4-9

Scanner left side cover removal

1. Remove the two screws (A).

2. Slide the cover toward the rear to unlatch the cover, and remove.
Note: Model 500S shown.

4-10 Service Manual

Front flatbed cover removal

Pull the top of the cover out first, and lift away to remove.

Scan cover (flatbed) removal

1. Remove the glass holder assembly. See Scanner flatbed glass holder assembly removal on
page 4-50.

2. Remove the flatbed contact glass. See Flatbed contact glass removal on page 4-31. 3. Remove the three screws (A).

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4. Lift the scan cover (flatbed). Scanner right side cover removal

Scanner right side cover removal

1. Remove the screw (A).

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2. Slide cover back to release tab (B).

ADF attach screws removal

1. Open the document cover. 2. Remove the two ADF attach screws (A) by turning them by hand.

A
Note: Do not remove the screws toward the rear.

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ADF CCD module assembly removal (model 500S)

1. 2. 3. 4. 5. 6.
Remove the ADF assembly. See ADF complete assembly removal on page 4-15. Remove the ADF front cover. See ADF front cover removal on page 4-6. Remove the flatbed white cushion. See Flatbed white cushion removal on page 4-32. Turn the ADF assembly upside down, carefully supporting the unit. Open the lower exit guide assembly. Remove the four screws (A) and the two small screws (B) securing the ADF CCD module assembly.

7. Remove the ADF jam tray sensor (C) from the mounting bracket to protect it from being bumped or
damaged during removal of the ADF CCD module assembly.

8. Remove the ADF CCD module assembly, and disconnect the ADF CCD to scan control cable (D).

C
Reinstallation notes:

Be sure to avoid touching the glass of the new FRU during installation. Be sure to reinstall the ADF jam tray sensor. 4-14 Service Manual

ADF complete assembly removal

1. Twist the thumbscrews to disconnect the cable(s) (A) at the back of the ADF assembly.
Note: Model 450S has a single cable. Model 500S Model 450S

2. Remove the ADF attach screws. See ADF attach screws removal on page 4-13.
Note: Do not remove the two screws in the back.

3. Lift the ADF up, and make sure you clear the two rear screws. The hinge is slotted to allow the ADF to
come off and leave the screws in place.

Note: Whenever the complete ADF assembly is replaced, it is necessary to perform the scanner registration. See Scanner registration on page 4-4.

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ADF upper entrance guide assembly removal

1. Remove the ADF pick assembly. See ADF pick assembly removal on page 4-7. 2. Remove the document tray assembly. See Document tray assembly removal on page 4-23. 3. Remove the three screws (A).

4. Lift the cover.

Replacement note: Be sure to align the tabs.

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CCD belt removal

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the flatbed contact glass. See Flatbed contact glass removal on page 4-31 3. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

4. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 5. Push the CCD belt tension spring to take tension from the belt. 6. Unhook the belt from the motor shaft.

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7. Push the flatbed CCD all the way to the left. 8. Unhook the main CCD guide shafts (E) from the holes in the right side. This allows you to remove the
flatbed CCD module from the shafts.

9. Carefully lay the flatbed CCD module on the scan frame, being careful not to touch the card, lamp, or
mirrors.

10. Disconnect the CCD belt from the retainer (F) in the flatbed CCD module assembly.

11. Remove the CCD belt.

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CCD belt tension spring removal

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the flatbed contact glass. See Flatbed contact glass removal on page 4-31. 3. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

4. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 5. Push the CCD belt tension spring toward the motor to take tension from the belt. 6. Unhook the belt from the motor shaft.

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7.

Unhook the main CCD guide shaft (A) from the hole in the right side, and slide it out of the way. This allows you to access the spring.

8.

Remove the CCD belt tension spring (A).

4-20 Service Manual

Cover closing actuator removal

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

3. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 4. With pliers, pull firmly to remove the actuator (A).

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Cover closed actuator removal

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

3. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 4. With pliers, pull firmly to remove the actuator (A).

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Document tray assembly removal

1. Remove the ADF front cover. See ADF front cover removal on page 4-6. 2. Remove the ADF rear cover. See ADF rear cover removal on page 4-7. 3. Remove the two screws (A).

4. For model 500S, disconnect the connector (B).

Models 500S

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Flatbed CCD ribbon cable removal

Illustrations represent model 500S. Unless there is an indication, the procedure is the same. Differences are shown side by side.

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the flatbed contact glass. See Flatbed contact glass removal on page 4-31. 3. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

4. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 5. Push the flatbed CCD toward the motor to take tension from the belt. 6. Unhook the belt from the motor shaft.

7. Push the flatbed CCD all the way to the left.

4-24 Service Manual

8. Unhook the main CCD guide shafts (A) from the holes in the right side. This allows you to remove the
flatbed CCD module from the shafts.

9. Carefully lay the flatbed CCD module on the scan frame, being careful not to touch the card, lamp, or
mirrors.

10. Disconnect the flatbed CCD ribbon cable (B) from the flatbed CCD module.

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11. Remove the screw (C) from the flatbed CCD ribbon cable clamp.

12. Remove the printer left side cover. See Printer left side cover removal on page 4-56. 13. Remove the seven screws (D) from the SCC and HDD shield. (Model 500S)

4-26 Service Manual

14. Loosen the screws for the printer outer shield, and slide shield to the left to allow enough room to remove
the scanner control card shield and the hard disk shields.

15. Disconnect the flatbed CCD ribbon cable from the scanner control card (E).
Model 500S Model 450S

16. Remove the toroid from the cable, and set aside for reinstallation. 17. Disconnect the flatbed CCD ribbon cable from the IF interface card.

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Flatbed CCD module assembly removal

Illustrations represent model 500S. Unless there is an indication, the procedure is the same. Differences are shown side by side.

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the flatbed contact glass. See Flatbed contact glass removal on page 4-31. 3. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

4. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 5. Push the CCD belt tension spring to take tension from the belt. 6. Unhook the belt from the motor shaft.

4-28 Service Manual

7. Push the flatbed CCD all the way to the left. There is a slot in the frame to allow the flatbed CCD module
assembly to be lifted out.

8. Unhook the main CCD guide shafts (E) from the holes in the right side. This allows you to remove the
flatbed CCD module assembly from the shafts.

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9. Disconnect the flatbed CCD ribbon cable (B) from the flatbed CCD module.

10. Disconnect the CCD belt from the retainer (C) in the flatbed CCD module assembly

11. Remove the flatbed CCD module assembly.

4-30 Service Manual

Flatbed contact glass removal

1. Open the document cover. 2. Remove the scanner flatbed glass holder assembly. See Scanner flatbed glass holder assembly
removal on page 4-50.

3. Remove the upper glass holder. See Upper glass holder removal on page 4-53. 4. Slide the glass to the left, and lift it.
CAUTION While the glass edge is beveled, handle it carefully to avoid cutting your hand.

5. Lift the glass, and place it on a clean, dry cloth.

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Flatbed white cushion removal

1. Open the document cover. 2. Peel the Velcro attached pad from one corner.

To replace the flatbed white cushion, place the cushion on the document glass, and close the document cover.

4-32 Service Manual

Flatbed interconnect card removal

Warning: When replacing any one of the following components:

Flatbed Interconnect card (ICC) System board assembly Interface card assembly
Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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. Observe all ESD precautions while handling ESD-sensitive parts. See Handling ESD-sensitive parts on page 4-1.

Warning:

Illustrations represent model 500S. Unless there is an indication, the procedure is the same. Differences are shown side by side.

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the flatbed contact glass. See Flatbed contact glass removal on page 4-31. 3. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

4. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 5. Remove the three screws (A) that attach the hinge support bracket to the rear scan bracket.

6. Remove the two screws (B) from the top. 7. Remove the two screws (C) from the left side and right side.

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8. Remove the two screws (D) from the left bottom and right bottom.

9. Disconnect all connectors (E). There are either four or three, depending on model. 10. Remove the four screws (F).
Model 500S Model 450S

11. Remove the card.

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Flatbed paper length sensor assembly removal

Illustrations represent model 500S. Unless there is an indication, the procedure is the same. Differences are shown side by side.

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the flatbed contact glass. See Flatbed contact glass removal on page 4-31. 3. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

4. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 5. Remove the three screws (A) that attach the hinge support bracket to the rear scan bracket.

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6. Remove the two screws (B) from the top. 7. Remove the two screws (C) from the left side and right side. 8. Remove the two screws (D) from the left bottom and right bottom.
Note: Some models may look different. Model 500S is shown.

9. Remove the two screws (E) from the sensor assembly cover.
Model 500S Model 450S

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10. Turn over the sensor cover, and remove the screw (F) for the sensor you need to replace.
Note: There are three sensors in model 500S. There is only one in model 450S

11. Disconnect the sensor cable (G) at the sensor and remove the sensor.
Note: Only remove one sensor at a time to make it easier to reinstall the right cable. Model 500S Model 450S

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Flatbed scan assembly removal

Illustrations represent model 500S. Unless there is an indication, the procedure is the same. Differences are shown side by side.

1. 2. 3. 4.

Remove the ADF assembly. See ADF complete assembly removal on page 4-15. Remove the printer left side cover. See Printer left side cover removal on page 4-56. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. Remove the seven screws (A) from the SCC and HDD shield.

5. Loosen the screws for the printer outer shield and slide shield to the left to allow enough room to remove
the scanner control card shield and the hard disk shield.

4-38 Service Manual

6. Disconnect the two cables (B).

Model 500S Model 450

7. Remove the two screws (C) from the left side. 8. Remove the two screws (D) that attaches the ground bracket to the SCC/HDD shield.
Note: The ground bracket is only on model 500S. Model 500S

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9. Remove the scanner right side cover. Lift the scan cover (flatbed). Scanner right side cover removal
on page 4-12.

10. Remove the two screws from the right side (E).

11. Pull the scan unit forward to unhook the unit from the printer, and lift the scan unit from the printer.

Installation note: Remove any clear protective covers from the scanner registration strip and the flatbed white cushion after installation.

4-40 Service Manual

Flatbed scan motor assembly removal

Illustrations represent models 500S. Unless there is an indication, the procedure is the same. Differences are shown side by side.

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the flatbed contact glass. See Flatbed contact glass removal on page 4-31. 3. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

4. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 5. Remove the three screws (A) that attach the hinge support bracket to the rear scan bracket.

6. Remove the two screws (B) from the top. 7. Remove the two screws (C) from the left side and right side.

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8. Remove the two screws (D) from the left bottom and right bottom.

9. Push the flatbed CCD toward the motor to take tension from the CCD belt. 10. Unhook the CCD belt from the motor shaft.

11. Carefully lay the flatbed CCD module on the scan frame, being careful not to touch the card, lamp, or
mirrors.

4-42 Service Manual

12. Remove the three screws (E) that attach the FB scan motor assembly to the frame.

13. Remove the flatbed scan motor assembly.

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Hard disk removal

Note: This procedure applies to model 500S only.

1. Remove the printer left side cover. See Printer left side cover removal on page 4-56. 2. Remove the six screws (A) from the SCC and HDD shield.

3. Loosen the screws for the printer outer shield, and slide the shield to the left to allow enough room to
remove the scanner control card shield and the hard disk shield.

4. Disconnect the two cables (B).

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5. Remove the four screws (C).

6. Remove the hard disk.

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Home sensor removal

1. Remove the scan cover (flatbed). See Scan cover (flatbed) removal on page 4-11. 2. Remove the flatbed contact glass. See Flatbed contact glass removal on page 4-31. 3. Remove the scanner right side cover. See Lift the scan cover (flatbed). Scanner right side cover
removal on page 4-12.

4. Remove the scanner left side cover. See Scanner left side cover removal on page 4-10. 5. Remove the screw (A).

6. Remove the sensor and bracket (B). 7. Disconnect the cable (C) from the sensor. 8. Unclip the home sensor (D) from the bracket.

4-46 Service Manual

Lower exit guide assembly removal

Illustrations represent model 500S. Unless there is an indication, the procedure is the same. Differences are shown side by side.

1. 2. 3. 4. 5.

Remove the ADF front cover. See ADF front cover removal on page 4-6. Remove the flatbed white cushion. See Flatbed white cushion removal on page 4-32. Open the document cover. Press the latch (A) to open the lower exit guide assembly. Remove the two screws (B), and remove the metal plate (C). Set the plate aside.

6. Remove the screw (D) on the ADF frame.

7. Remove the lower exit guide assembly.

Installation note: Be sure to route the cable through the hole (E) in the front ADF frame.

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Pickup solenoid assembly removal

1. Remove the two screws (A). 2. Unhook the spring (B).
Note: Two springs attach to the same post. The other spring should be hooked on first, and spring (B) should be attached on the outside or in front of the other spring.

3. Remove the cable from the cable guide. 4. Disconnect the connector (C), and remove the pickup solenoid assembly.

Scanner control card removal

Illustrations represent model 500S. Unless there is an indication, the procedure is the same. Differences are shown side by side.

1. Remove the printer left side cover. See Printer left side cover removal on page 4-56. 2. Remove the six screws (A) from the SCC and HDD shield.

4-48 Service Manual

3. Loosen the screws for the printer outer shield, and slide the shield to the left to allow enough room to
remove the scanner control card shield and the hard disk shield.

4. Disconnect all the cables (B).

Model 500S shown) Model 450S

5. Remove the four screws (B). 6. Tilt the card to remove the scanner control card.

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Scanner flatbed glass holder assembly removal

1. Open the document cover. 2. Remove the two screws (A).

3. Carefully pry up the inner edge.

Warning: Do not use tools that can scratch the glass.

Warning:

Be careful not to touch the calibration strip (A) on the underside of the scanner flatbed glass holder.

4-50 Service Manual

4. Lift to release the three tabs (C).

Warning: Place the scanner flatbed glass holder assembly on a clean, dry cloth to protect the glass from scratches. Do not touch the calibration strip (D.)

Warning:

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Separator assembly torque limiter removal

1. Open the ADF top cover. 2. Remove the ADF pick arm assembly. See Document tray assembly removal on page 4-23. 3. Unsnap and remove the paper guide (A).

4. Remove the clip (B). 5. Remove the reverse roller (C). 6. Slide the separator assembly torque limiter (D) off the shaft.

4-52 Service Manual

Upper glass holder removal

1. Open the document cover. 2. Slide the upper glass holder to the left to unlatch.

3. Lift the upper glass holder to remove.

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Printer removals
CAUTION Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. CAUTION Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down. Note: Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.

Fuser wiper cover assembly removal

1. Squeeze the two latches together, and pull up.

2. Remove the fuser wiper cover assembly. 3. Remove the fuser wiper cover assembly.

4-54 Service Manual

Upper sub cover removal

1. Remove flatbed scanner assembly. See Flatbed scan assembly removal on page 4-38. 2. Remove screw (A) from right side frame holding upper sub cover.

3. Pull up on the right side of the upper sub cover. 4. Remove the upper sub cover.

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Upper tray cover removal (paper support)

1. Remove the flatbed scan assembly. See Flatbed scan assembly removal on page 4-38. 2. Raise the upper tray cover, and lift to release the latches.

3. Remove the upper tray cover.

Printer left side cover removal

1. Open the upper and lower front covers. 2. Press the two left door latch buttons (A), and open the left door.

4-56 Service Manual

3. Release the top hinge from the latch (B).

4. Lift the door to release the bottom from the pin (B), and remove the door.

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Redrive door
1. With the redrive door partially open, lift and free the left side.

2. Remove the redrive door.

Printer right cover removal

1. 2. 3. 4.
Remove the upper sub cover. See Upper sub cover removal on page 4-55. Open the upper and lower front covers. Remove the print cartridge. Remove the right front cover mounting screw (A).

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5. Remove the redrive door. See Redrive door on page 4-58. 6. Remove the right rear cover mounting screw (C).

7. Remove the two redrive screws (D). 8. Press the two latches to remove the redrive assembly.

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9. Press the latch (D) firmly to release the front of the right cover.

10. Pull up and out on the right cover to release the three cover retainers (E) at the bottom.

E
Note: When replacing the right side cover, make sure the three cover retainers (E) are correctly located in the appropriate slots in the right side frame.

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Operator panel left cover assembly removal

Illustrations represent model 500S. Unless there is an indication, the procedure is the same.

1. Remove the printer left side cover. See Printer left side cover removal on page 4-56. 2. Open the printer upper front cover. 3. Remove the two screws (A).

4. For model 450S, disconnect the cable (B).

Model 450S

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5. For model 450S, remove the screw (C) that attaches the ground cable.

6. Remove the operator panel left cover assembly.

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Installation note: Be sure the latches (C) on the back of the operator panel left cover are fastened into the upper front cover hinge slots.

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Operator panel right cover assembly removal

1. Open the printer upper front cover. 2. Remove the two screws (A).

3. Lift the operator panel right cover assembly carefully to access the cables.
Warning: Be careful not to tear or break the small ribbon cable from its connector (B).

4. Disconnect the four cables (C) from the UI control card.

5. Remove the operator panel right cover assembly.

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Installation note: Be sure the latches (D) on the top of the operator panel right cover are fastened into the upper front cover hinge slots.

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Touchscreen bezel removal

1. Open the printer upper front cover. 2. Use a small screwdriver or other small tool to carefully release the two tabs (A) under the touchscreen
bezel. Warning: Be careful not to scratch or mar the touchscreen bezel. Model 450S

Model 500S

3. For model 450S, disconnect the UICC#3 cable (B).

4. Remove the touchscreen bezel.

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LCD touchscreen removalmodel 500S

CAUTION When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.

1. Remove the operator panel left front cover. See Operator panel left cover assembly removal on
page 4-61.

2. Remove the two screws (A) on the operator panel right front cover.

3. Lift the operator panel right cover assembly carefully to access the cables.
Warning: Be careful not to tear or break the small ribbon cable from its connector (B).

4. Disconnect the cables (C) from the UI control card.

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5. Remove the operator panel left side cover. See Operator panel left cover assembly removal on
page 4-61.

6. Disconnect the cable (D) from the LCD inverter card assembly.

7. Remove the touchscreen bezel. See Touchscreen bezel removal on page 4-66. 8. Press the two tabs (E) that limit range of motion, and rotate the LCD touchscreen up until it disconnects.

9. Set the LCD touchscreen aside.

Warning: Avoid touching or placing pressure on the touchscreen. Do not handle roughly or drop.

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10. Disconnect the ground cable. You might want to use a pair of pliers and a small flat blade screwdriver.

LCD touchscreen removalmodel 450S

1. Remove the bezel. See Touchscreen bezel removal on page 4-66. 2. Remove the two screws (A) from the right side cover.

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3. Lift the operator panel right cover assembly carefully to access the cables.
Warning: Be careful not to tear or break the small ribbon cable (B) from its connector.

4. Disconnect the cables (C) from the UI CC#.

B
page 4-61.

5. Remove the operator panel left side cover. See Operator panel left cover assembly removal on 6. Use a screwdriver to lift the lock and disconnect the cable (D) from the LCD inverter card assembly.

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7. Press the two tabs (E) that limit range of motion, and rotate the LCD touchscreen up until it disconnects.

Multipurpose feeder/lower front cover assembly removal

1. Open the multipurpose tray to a position that allows the left and right tray hinge slots (A) to align with the
D-shape mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts. Warning: Be careful not to break or stress the hinges.

2. Remove the multipurpose tray/lower front cover assembly.

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Left cover handle holder removal

1. 2. 3. 4.
Open the left side cover. Remove the outer system board shield. See Printer outer shield removal on page 4-126. Remove the two screws (A) holding the top of the left handle holder in place. Use the tab (B) to lift out the left handle holder.

Right cover handle holder removal

1. Remove the right side cover. See Printer right cover removal on page 4-58. 2. Remove the two screws (A) holding the top of the right handle holder in place. 3. Lift out the right handle holder.

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Left and right frame extensions

1. 2. 3. 4. 5.
Remove the ADF and flatbed scanner assemblies. See Flatbed scan assembly removal on page 4-38. Remove the toner cartridge. Turn the printer on its back. Remove the two screws (A) holding the right frame extension. Remove the two screws (B) securing the left frame extension.

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Pass thru plate

1. Remove the redrive assembly. See Redrive assembly removal on page 4-128. 2. Remove the screw (A) securing the pass thru plate.

3. Carefully remove the plate until it is loose. 4. Remove the fuser to system board DC cable (B) secured through the plate.
Note: Note the routing of the fuser card to system board DC cable.

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Bevel gear removal

1. 2. 3. 4.
Open the left door. Remove the inner shield. Remove the gear guard. Remove the power takeoff shaft and spring (A) through the bottom of the printer.

5. Place your thumb on the top of the gear, and press firmly down and away.
Note: You need to exert firm pressure to snap the bevel gear out.

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Installation 1. Remove any washer that may be present (A) and discard. 2. Lubricate areas (A) that engage the journal (B) with grease from the provided packet. 3. Place the new washer (C) on the bevel gear shaft.

4. Insert the bottom portion and press or pull into position.

Note: You should hear two distinct snaps. If you only hear one, the bevel gear is only partially engaged and you should continue to press until the second snap is heard. Very firm pressure is required. CAUTION Do not brace your hands below the bevel gear itself. When the gear double-snaps into place, it may pinch your hand.

5. Install the power takeoff shaft and spring. 6. Install the gear guard. 7. Install the inner shield.

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Developer drive assembly removal

1. Remove the system board and inner shield. See System board and inner shield removal model
500S on page 4-131.

2. Remove the two short screws (A) and the one long screw (B) securing the developer drive assembly.

3. Remove the developer drive assembly. 4. Remove the developer drive coupler kit. See Developer drive coupler kit removal on page 4-78. Installation 1. Place the developer coupler into the main motor drive shaft. 2. Place the developer drive shaft on the developer drive. 3. Align the developer drive shaft with the coupler.

4. Be sure to replace the screws in the same positions.

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Developer drive coupler kit removal

1. Remove the developer drive. See Developer drive assembly removal on page 4-77. 2. Remove the shaft drive and coupler.

ESD cover removal

1. Open the multipurpose tray, and remove the tray from the two mounting posts. See Multipurpose feeder/
lower front cover assembly removal on page 4-71.

2. Carefully lift the latch on the left (A), and remove the ESD cover.
Note: Be careful not to stress the hinge on the right (B).

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Fuser assembly removal

CAUTION Unplug the printer before you begin.

1. Remove the fuser wick assembly cover. See Fuser wiper cover assembly removal on page 4-54. 2. Remove the redrive assembly. See Redrive assembly removal on page 4-128. 3. Remove the fuser mounting screws (A).

4. Disconnect the fuser to LVPS AC cable (B) from the fuser lamp connector (C).

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5. Disconnect the fuser to system board DC cable (D) from the fuser board.
Note: Be sure to observe the routing of the LVPS to fuser lamp AC and the DC cable.

6. Pull the cables free and remove the fuser. Installation notes 1. When you reinstall the fuser, be sure to route the fuser to LVPS AC cable (A) through the channel (B) on
the right side frame above the LVPS, under the clip (C) over the LVPS, and through the notch in the frame (D).

2. Route the fuser lamp cable through the opening in the fuser (E).

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3. Connect the fuser to LVPS AC cable to the fuser lamp connector (F) at the LVPS.
Note: Be sure to connect the fuser to system board DC cable after replacing the LVPS.

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Fuser exit sensor removal

1. 2. 3. 4.
Remove the fuser. See Fuser assembly removal on page 4-79. Disconnect the fuser exit cable (A) from the fuser control board. Remove the screw (B) securing the cover containing the fuser exit sensor, flag, and spring. Release the two clips (C) holding the sensor in the bracket.

5. Unplug the fuser exit sensor cable from the sensor. Installation 1. Move the fuser exit sensor flag out of the way to clip the sensor securely into the cover.

2. Connect the fuser exit sensor cable.

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3. Snap the bottom fastener of the sensor cover into place in the lower exit guide assembly, and use a small
flat bladed screwdriver to ease the sensor cover into the clips.

4. Replace the screw securing the sensor cover.

Note: Make sure the flag moves properly.

Fuser exit sensor flag and spring removal

1. Remove the fuser exit sensor. See Fuser exit sensor removal on page 4-82. 2. Note the position of the spring (A) in relation to the flag (B). 3. Carefully ease the right arm (C) until the fuser exit sensor cover releases the flag and spring.

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Spring replacement 1. Place the spring on the left pin (A). 2. Set the tang (B) on the flag.

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3. Rotate the bent end (C) of the spring to add tension, place the pins between the sensor cover arms, and
rest the bent end against the sensor cover frame.

Note: After replacing the sensor, flag, and spring, make sure the flag moves freely and returns.

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Fuser lamp removal

CAUTION The fuser and the fuser lamp may be hot. You may need to allow them to cool before handling them.

1. Remove the fuser assembly. See Fuser assembly removal on page 4-79. 2. Disconnect the fuser lamp AC cable from the right side of the top cover assembly. 3. Remove the two screws (A) from the right side fuser lamp contact cover.
Warning: Take care when removing the screw, as the lamp is under spring tension. When the contact is released, damage to the lamp or contact may occur.

A(202)

4. Remove the left lamp contact assembly.

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5. Remove the fuser lamp.

Warning: The lamp is under spring tension, and care must be used when removing the lamp from the fuser. Grip the lamp by the ceramic end piece, and remove it from the fuser assembly. Be careful not to touch the glass, as skin oils and acids can reduce the life of the lamp.

Use the following table to identify and install the correct lamp. Description Fuser Lamp 115 V Fuser Lamp 220 V P/N 40X0122 40X0123

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Fuser narrow media sensor removal

1. Remove the redrive assembly. See Redrive assembly removal on page 4-128. 2. Remove the screw (A) securing the narrow media sensor cover to the fuser. 3. With a thumbnail, release the catches (B) holding the sensor cover to the lower exit guide assembly (C) in
place. Note: You may need to move the narrow media flag out of the way to remove the sensor.

4. Disconnect the fuser narrow media cable at the sensor. 5. Release the catches holding the sensor in the cover.
Note: Hold the narrow media flag out of the way to remove the sensor from the cover.

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Replacement 1. Move the narrow media flag out of the way to clip the sensor securely into the cover.

2. Connect the fuser narrow media cable. 3. Snap the bottom fastener of the sensor cover into place in the lower exit guide assembly, and rock the
cover up until the top fastener snaps securely.

4. Replace the screw securing the sensor cover.

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Fuser narrow media flag and spring removal

1. Remove the fuser narrow media sensor. See Fuser narrow media sensor removal on page 4-88. 2. Note the position of the spring (A) in relation to the flag (B). 3. Carefully ease the right arm (C) of the sensor cover just far enough apart to release the flag and spring.

Spring replacement 1. Place the spring on the left pin (A). 2. Set the tang (B) on the flag.

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3. Rotate the bent end (C) of the spring to add tension, place the pins between the sensor cover arms, and
rest the bent end against the sensor cover frame.

A
Note: After replacing the sensor, flag, and spring, make sure the flag moves properly.

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Fuser to LVPS AC cable removal

CAUTION Unplug the printer before you begin.

1. 2. 3. 4.

Remove the fuser wick assembly cover. See Fuser wiper cover assembly removal on page 4-54. Remove the redrive assembly. See Redrive assembly removal on page 4-128. Remove the right side cover. See Printer right cover removal on page 4-58. Disconnect the fuser to LVPS AC cable (A) from the fuser lamp connector on the fuser, and remove the cable through the cable retainer (B) and the lower rectangular opening (C) in the fuser frame.

5. Remove the pass thru plate. See Pass thru plate on page 4-74. 6. Disconnect the LVPS to system board DC cable (D) from the LVPS.

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7.

106 Pull

the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS AC cable from the LVPS (E). Note: The LVPS assembly may be difficult to remove from the printer. Do not use excessive force in the removal.

8. Remove the fuser to LVPS AC cable. Installation 1. Plug in the fuser to LVPS AC cable (A) into the LVPS. 2. Route the cable through the channel (B) on the right side frame above the LVPS, under the clip (C) over the
LVPS, and through the notch in the frame (D).

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3. Route the cable through the lower rectangular opening (E). 4. Connect the fuser to LVPS AC cable to the fuser lamp connector (F).

Note: Be sure to connect the fuser to system board DC cable after replacing the LVPS.

4-94 Service Manual

Fuser top cover removal

CAUTION Unplug the printer before you begin.

1. Remove the fuser assembly. See Fuser assembly removal on page 4-79. 2. Note the thermistor cable routing (A) and disconnect the thermistor cable at the fuser control board.

3. Disconnect the AC fuser lamp cable (B) from the top right side of the fuser cover.

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4. Carefully remove the two screws (C) from the right side of the fuser lamp contact cover (D). 5. Release the latch (E) and remove the cover.

6. Remove the screw (F) on the left side and the screw (G) on the right side that attach the fuser upper cover
assembly to the fuser frame.

7. Remove screw (H) that attaches the side fuser lamp contact to the fuser top cover.

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8. Remove the fuser cover.

Fuser transfer plate removal

1. 2. 3. 4.
Remove the upper paper deflector. See Upper paper deflector assembly removal on page 4-138. Remove the transfer roll. See Transfer roll assembly removal on page 4-132. Remove the inner paper deflector. See Inner paper deflector assembly removal on page 4-101. Lift the left side of the fuser transfer plate (A), and move the plate to the left to clear the right side from its mounting.

5. Remove the screw that attaches the transfer plate ground wire to the center pan. 6. Remove the fuser transfer plate. 7. Remove the screw that attaches the deflector cable to the transfer plate.

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Gear release link removal

1. Remove the system board and inner shield. See System board and inner shield removal model
500S on page 4-131.

2. Remove the developer drive. 3. Disconnect the gear release link (A) from the hole in charge roll link (B).
Note: Lift the upper front cover to make it easier to remove the link.

4. Rotate the link to disconnect the link from the main drive assembly.

5. Remove the gear release link.

4-98 Service Manual

High voltage power supply removal

CAUTION 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.

1. Remove the inner paper deflector. See Inner paper deflector assembly removal on page 4-101. 2. Remove the right side cover. See Printer right cover removal on page 4-58. 3. Disconnect the HVPS cable from the HVPS at connector (A).

4. Disconnect the transfer roll cable (B) from the HVPS board.
Warning: Use care when disconnecting the cable from the transformer on the HVPS. The cable and connector can be easily damaged.

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5. Remove the HVPS mounting screws (C).

6. Slide the HVPS to the left to release the mounting tab from the center pan, and remove the HVPS.

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Inner paper deflector assembly removal

1. Remove the paper tray. 2. Remove the upper paper deflector assembly. See Upper paper deflector assembly removal on
page 4-138.

3. Remove the MPF lower deflector assembly. See MPF lower paper deflector on page 4-117. 4. Place the printer on its side. 5. Gently pry the inner paper deflector from the left and right mounting posts (A) located on the bottom of the
printer, and remove the deflector.

6. Disengage the two latches (B) on the upper part of the deflector from the upper edge of the frame (C), and
lift to remove.

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Input sensor removal

1. Remove the upper paper deflector. Upper paper deflector assembly removal on page 4-138. 2. Loosen the MPF lower front cover. See Multipurpose feeder/lower front cover assembly removal on
page 4-71.

3. Remove the inner paper deflector.Inner paper deflector assembly removal on page 4-101. 4. Disconnect the input sensor cable (A) from the input sensor (B). 5. Release the input sensor from its mounting, and remove.

4-102 Service Manual

Integrated tray autocompensator assembly removal

1. 2. 3. 4. 5. 6. 7.
Remove the ADF scanner assembly. See ADF complete assembly removal on page 4-15. Remove the flatbed scanner assembly. See Flatbed scan assembly removal on page 4-38. Remove the paper tray. Remove the left door. See Printer left side cover removal on page 4-56. Remove the outer shield. See Printer outer shield removal on page 4-126. Place the printer on its back. Disconnect the cannot motor cable (A) from the system board (J24).

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8. Locate the integrated tray autocompensator assembly (B) on the bottom of the printer, and disconnect the
autocompensator arm bias spring (C). Note: When you remove the spring, note the larger loop attaches to the side frame.

9. Remove the C-clip (D) that rests against the right side frame from the autocompensator pivot shaft.

10. Disconnect the autocompensator sensor cable (E) from the assembly. 11. Remove the autocompensator assembly mounting screw (F).

12. Slide the shaft to the right, and push the shaft from the outside of the frame. 13. Remove the integrated tray autocompensator assembly.

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Integrated tray autocompensator pick roll assembly removal

1. Remove the integrated tray, and look underneath the printer for the autocompensator arm. Pull the arm
down.

2. Press on the end of the tab (A) and pull the pick roll off the arm. Repeat this step for the pick roll on the
other side. Next, gently release the autocompensator arm. Discard the used pick rolls.

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Installation 1. Remove the new pick rolls from their packaging. 2. Pull the autocompensator arm down. Locate the recessed area on the pick roll, and align it with the tab on
the arm. There are two arrows on each pick roll. Make sure the bottom arrow faces you as you align the recessed area with the tab.

3. Push the pick roll onto the arm with the tab aligned. Repeat this step on the other side to install the other
pick roll.

4. Gently release the autocompensator arm. Insert, integrated tray.

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Interface card assembly removal

CAUTION Unplug the printer before you begin.

Warning:

When replacing any one of the following components:

Flatbed Interconnect card (ICC) System board assembly Interface card assembly
Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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. Observe all ESD precautions while handling ESD-sensitive parts. See Handling ESD-sensitive parts on page 4-1.

Warning:

Note: Any time the interface card assembly is replaced, the Configuration ID must be reset in NVRAM on the new interface card. Go to Configuration ID on page 3-19.

1. Remove any feature or option cards from the interface card. 2. Remove modem card (A) if installed. 3. Remove the two screws securing the interface card (B).

4. Remove the interface card assembly.

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LCD inverter card assembly removal

1. Remove the printer left side cover. See Printer left side cover removal on page 4-56. 2. Remove the operator panel left side cover. See Operator panel left cover assembly
removal on page 4-61.

3. Remove the two cables (A). 4. Remove the two screws (B).
Model 500S Model 450S

Note: For model 450S, you may need to carefully use a screw to disconnect the LCD display HV cable (C). Model 450S

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Low voltage power supply removal

CAUTION Unplug the printer before you begin.

1. 2. 3. 4. 5.

Remove the redrive assembly. See Redrive assembly removal on page 4-128. Remove the right side cover. See Printer right cover removal on page 4-58. Remove the pass thru plate. See Pass thru plate on page 4-74. Remove the LVPS mounting screws (A) from the rear of the center pan. Disconnect the LVPS to system board cable. The cable is difficult to disconnect. There are catches (B) that firmly hold latches on the LVPS card connector (C).

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6. Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS
AC lamp cable (D). Warning: The LVPS assembly may be difficult to remove from the printer. Do not use excessive force in the removal.

7. Remove the low voltage power supply.

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Main fan removal

1. 2. 3. 4. 5. 6.
Remove the ADF scanner assembly. See ADF complete assembly removal on page 4-15. Remove the flatbed scanner assembly. See Flatbed scan assembly removal on page 4-38. Remove the printer left side cover. See Printer left side cover removal on page 4-56 Open the left side cover. Remove the outer shield. See Printer outer shield removal on page 4-126. Remove the two screws (A) securing the upper plenum.

7. Remove the upper plenum.

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8. Clip the cable tie (B).

Note: Be careful not to damage any of the cables. Note the location of the cable tie for later replacement.

9. Disconnect the main fan to the system board (C) at J4.

10. Remove the main fan.

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Main drive assembly removal

1. Remove the system board and inner shield. See System board and inner shield removal model
500S on page 4-131.

2. Remove the screw securing the gear guard (A).

3. Remove the power take off shaft and spring. See Power takeoff shaft and spring removal on
page 4-126.

4. Remove the developer drive assembly. See Developer drive assembly removal on page 4-77. 5. Lift and remove the cables from the cable hooks (B).

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6. Remove the ground cable screw (C). 7. Remove the main drive assembly mounting screws (D).

8. Disconnect the gear release link (E) from the hole in the charge roll link (F).
Note: Lift the upper front cover to make it easier to remove the link.

9. Disconnect the main drive motor cable from the main drive assembly. 10. Remove the main drive assembly.
Warning: Whenever the main drive assembly is removed from the printer it must be handled very carefully. Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage. It is also very important not to let any dirt, paper, staples, or other material come in contact with the grease in the gears.

Note: Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly.

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Modem removal
1. Remove the two screws (A) on the rear of the MFP.

2. Disconnect the cable (B) from the scanner control card. 3. Remove the cable from the slot in the frame (C). 4. With a flathead screwdriver open the cable clamp (D), and remove the cable and the modem.

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MPF arm assembly removal

1. Open the left door. 2. Remove the MPF lower front cover. See Multipurpose feeder/lower front cover assembly removal on
page 4-71.

3. 4. 5. 6. 7.

Remove the MPF lower paper deflector. See MPF lower paper deflector on page 4-117. Remove the upper paper deflector. See Upper paper deflector assembly removal on page 4-138. Remove the inner paper deflector. See Inner paper deflector assembly removal on page 4-101. Remove the MPF solenoid assembly. See MPF solenoid assembly removal on page 4-119. Remove the C-clip (A).

8. Remove the washer, and set it aside.

9. Remove the MPF arm assembly.

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Installation note: Note the order of C-clips bushing, and washer when you reinstall.

MPF lower paper deflector

1. Remove the MPF lower cover. 2. Remove the four screws securing the MPF lower paper deflector.

3. Remove the defector.

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MPF pick tire removal

1. Remove the upper paper deflector. See Upper paper deflector assembly removal on page 4-138. 2. Release the pick roll retaining tab (A), and slide the pick roll off the shaft.

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MPF solenoid assembly removal

1. Open the left door. 2. Remove the MPF lower front cover. See Multipurpose feeder/lower front cover assembly removal on
page 4-71.

3. Remove the MPF lower paper deflector. See MPF lower paper deflector on page 4-117. 4. Remove the upper paper deflector. See Upper paper deflector assembly removal on page 4-138. 5. Remove the C-clip (A) on the left side.

6. Press the clips on the end of the shaft to remove the MPF tires (B). 7. Remove the C-clip (C) on the shaft.

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8. Remove the bushing (D).

Note: The bushing fits into a detent (E) in the frame of the MPF arm assembly.

9.

Loosen the paper alignment screws (F).

10. Remove the C-clip securing the MPF solenoid assembly on the shaft.
Note: This C-clip is very difficult to locate and remove.

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11. Pull the shaft assembly (G) to the right until the left end of the shaft is clear of the frame, and slide the MPF
solenoid assembly from the shaft.

Installation note: Be careful not to lose the washer (H) that is between the MPF solenoid assembly and the C-clip. It belongs to the MPF arm assembly.

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Paper alignment assembly removal

1. Remove the upper paper deflector assembly. See Upper paper deflector assembly removal on
page 4-138.

2. Remove the inner paper deflector assembly. See Inner paper deflector assembly removal on
page 4-101.

3. Release the input paper sensor from its mounting, and remove. 4. Remove the left door. 5. Remove the paper alignment assembly mounting screws (A).

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6. Locate the paper alignment assembly reference adjustment screw (B) through the left frame, and remove
the screw.

7. Remove the paper alignment assembly.

Note: Do the Paper alignment assembly adjustment on page 4-3 when you reinstall the assembly.

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Paper bin full sensor flag removal

1. 2. 3. 4.
Remove the left door. See Printer left side cover removal on page 4-56. Remove the upper sub cover. See Upper sub cover removal on page 4-55. Remove the fuser wiper cover assembly. See Fuser wiper cover assembly removal on page 4-54 Remove the two screws (A) attaching the upper plenum and remove the upper plenum.

5. Remove the screws from the upper cover. See Upper cover removal (printer) on page 4-133.
Note: It is not necessary to remove the cover from the printer.

6. Lift the left rear corner of the printer upper top cover to access the flag (B) and remove the flag from the
mounting bracket.

4-124 Service Manual

Paper size sensing board removal

1. Remove the system board and inner shield. See System board and inner shield removal models
X644e/X646e on page 4-131.

2. Remove the paper size sensing board mounting screw (A). 3. Disconnect the paper size sensing board cable (B) from the board. 4. Remove the paper size sensing board from the latch (C).

5. Remove the paper size sensing board.

Repair information

4-125

Power takeoff shaft and spring removal

Remove the power takeoff shaft and spring (A) through the bottom of the printer.

Printer outer shield removal

1. Remove the printer left door. See Printer left side cover removal on page 4-56. 2. Loosen the outer shield mounting screws (A), and remove the shield by sliding up.
A(202)

A(202)

4-126 Service Manual

Printhead removal
CAUTION The laser scanning unit is not a serviceable FRU. Replace the entire unit when service is required.

1. 2. 3. 4. 5.

Remove the ADF scanner. See ADF complete assembly removal on page 4-15. Remove the flatbed scanner. See Flatbed scan assembly removal on page 4-38. Remove the printer upper cover. See Upper cover removal (printer) on page 4-133. Disconnect the printhead cable (A) from the printhead assembly. Remove the four printhead mounting screws (B), and remove the printhead.

Note: Do the Printhead assembly adjustmentprinter on page 4-2 whenever you remove or replace the printhead assembly or loosen the mounting screws.

Repair information

4-127

Redrive assembly removal

1. 2. 3. 4.
Remove the redrive door assembly. Remove the redrive exit cover. Remove the redrive assembly mounting screws (A). Release the redrive assembly mounting latches (B), and remove the redrive assembly.

4-128 Service Manual

Signature button contact assembly removal

1. 2. 3. 4. 5. 6.
Remove the print cartridge. Remove the left side door. See Printer left side cover removal on page 4-56. Remove the right cover. See Printer right cover removal on page 4-58. Remove outer system board shield. See Printer outer shield removal on page 4-126. Disconnect signature button cable from connector J14 on the system board. On models 200/210/400/410, remove the two screws (A) securing the blower duct.

7. Remove the signature button contact assembly mounting screw (B). 8. Remove the assembly signature button contact assembly.
Note: Be sure to route the cable in the same location, as shown (C), when replacing the assembly.

Repair information

4-129

System board and inner shield removalmodel 450S

Warning: When replacing any one of the following components:

Flatbed interconnect card (ICC) System board assembly Interface card assembly
Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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. Observe all ESD precautions while handling ESD-sensitive parts. See Handling ESD-sensitive parts on page 4-1.

Warning:

1. Remove the outer shield. See Printer outer shield removal on page 4-126. 2. Disconnect all cables from the system board.
Note: Sometimes cables may be difficult to remove. Be careful not to damage the connectors.

3. Remove all features and options from the interface card. 4. Depending on your printer model, remove the small USB port mounting screw (A).
Note: You may have additional screws in various models.

5. Depending on your printer model, remove the modem. See Modem removal on page 4-115. 6. Remove the six system board mounting screws (B).

Back view

Side view

A
7. Remove the system board and inner shield.

4-130 Service Manual

System board and inner shield removal model 500S

Warning: When replacing any one of the following components:

Flatbed interconnect card (ICC) System board assembly Interface card assembly
Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable. Warning: Never install and remove components listed 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. Observe all ESD precautions while handling ESD-sensitive parts. See Handling ESD-sensitive parts on page 4-1.

Warning:

1. Remove the outer shield. See Printer outer shield removal on page 4-126. 2. Disconnect all cables from the system board.
Note: Sometimes cables may be difficult to remove. Be careful not to damage the connectors.

3. Remove all features and options from the interface card. 4. Depending on your printer model, remove the small USB port mounting screw (A).
Note: You may have additional screws in various models.

5. Depending on your printer model, remove the modem. See Modem removal on page 4-115. 6. Remove the six system board mounting screws (B).

Back view

Side view

A
7. Remove the system board and inner shield.

Repair information

4-131

Toner sensor removal

1. Remove the right side cover. See Printer right cover removal on page 4-58. 2. Remove the toner sensor mounting screw (A). 3. Disconnect the toner sensor cable, and remove the toner sensor.

Transfer roll assembly removal

Warning: Be careful when handling the transfer roll. Wrap a piece of plain white paper around the charge roll to prevent contamination or damage.

1. Open the upper front cover, and remove the print cartridge. 2. Unsnap the transfer roll assembly from the left pivot arm. 3. Lift the transfer roll assembly toward the left, and remove it from the printer.

4-132 Service Manual

Upper cover removal (printer)

1. 2. 3. 4. 5. 6. 7. 8.
Remove the ADF scan assembly. See ADF complete assembly removal on page 4-15 Remove the flatbed scan assembly. See Flatbed scan assembly removal on page 4-38. Remove the left door. See Printer left side cover removal on page 4-56. Remove the right cover. See Printer right cover removal on page 4-58. Remove the upper tray cover. See Upper tray cover removal (paper support) on page 4-56. Remove the upper sub cover. See Upper sub cover removal on page 4-55. Remove the fuser wiper cover. See Fuser wiper cover assembly removal on page 4-54. Remove the two screws (A) attaching the upper plenum and remove the upper plenum.

9. Remove the screw (B) at the rear of the printer and the larger screw (C) at the front on the right side.

Repair information

4-133

10. Remove the two screws (D) from the top of the right side.

11. Remove the two screws (E) from the top of the left side.

12. For those models with a hard disk (500S), remove the hard disk. See Hard disk removal on
page 4-44.

4-134 Service Manual

13. Remove the screw (F) through the back of the shield or from the position shown.

14. Unlatch the front right and front left cover posts, and remove the upper cover.

Note: Make sure the paper bin full sensor (G) clears the opening will lifting the upper cover.

Repair information

4-135

Upper front cover hinge assembly removal

1. Remove the ADF scan assembly. See ADF complete assembly removal on page 4-15. 2. Remove the flatbed scan assembly. See Flatbed scan assembly removal on page 4-38. 3. Remove the operator panel left cover assembly. See Operator panel left cover assembly removal on
page 4-61.

4. Remove the operator panel right cover assembly. See Operator panel right cover assembly removal
on page 4-64.

5. Remove the touchscreen bezel. See Touchscreen bezel removal on page 4-66. 6. Remove the LCD touchscreen. See LCD touchscreen removalmodel 500S on
page 4-67.

7. 8. 9. 10.

Remove printer left side cover. See Printer left side cover removal on page 4-56. Remove printer right side cover. See Printer right cover removal on page 4-58. Remove the printer upper cover. See Upper cover removal (printer) on page 4-133. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins, and remove the pins. Note the pin orientation and the C-clip location on the inside of each hinge.

11. Detach the two springs (B) from the upper front cover hinges. 12. Detach two springs (C) from the left and right side of the hinge assembly.

13. Disconnect the USB cable and cover open switch cable from the system board and UICC (18-pin) to
scanner control card cable from the scanner control card.

4-136 Service Manual

14. Remove the screw (D) attaching the hinge right side cable retainer and removal the UICC (18-pin) to
scanner control card cable from the hinge arm.

15. Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the
mounting bracket.

16. Lift the left pivot arm from the bracket, and move the upper cover hinge assembly toward the left to clear
the right upper cover pivot arm from the mounting bracket.

17. Remove the upper front cover hinge assembly.

Repair information

4-137

Upper paper deflector assembly removal

1. Either lift the ESD cover out of the way or remove it. See ESD cover removal on page 4-78.
Note: The tabs holding the ESD cover are easily stressed or broken.

2. Lift the left side to release the small tab (A) on the left and the MPF flag (B) and slide the upper paper
deflector assembly to the right to unlatch the hooks (C) on the right. Note: Be careful not to put too much stress on the small tab (A) on the right.

3. Lift to remove the upper paper deflector assembly.

Installation note: Make sure the MPF flag (B) is in place.

4-138 Service Manual

USB card
1. Remove the printer left side cover. See Printer left side cover removal on page 4-56. 2. Remove the operator panel left cover. See Operator panel left cover assembly removal on
page 4-61.

3. Remove the USB cable (A) from the USB board assembly. 4. Remove the two screws (B) securing the USB board assembly.
Note: Model 500S shown.

5. Remove the USB card.

Repair information

4-139

4-140 Service Manual

5. Locations and connections Locations

Sensorsflatbed
Model 450S

Models 500S

Locations and connections

5-1

SensorsADF
Model 450S

Models 500S

5-2

Service Manual

Connections
System board
Model 500S Model 450S

Locations and connections

5-3

System board (see System board on page 5-3) connector pins

Connector J1 Interconnect card J2 Printhead (laser cable) 1 2 3 4 5 6 7 8 9 10 11 12 13 J3 Printhead (HSYNC)/mirror motor 1 2 3 4 5 6 7 8 9 10 11 12 J4 Main fan 1 2 3 J5 Cartridge fan 1 2 3 J6 Hopper full (output bin sensor) 1 2 3 FANSTALL Ground MAINFAN CARTFANSTAIL Ground CARTFAN HOP FULL* Ground HOP LED VIDEO 1+ CN VIDEO 1- CN Ground LADJ2* VIDEO 0- CN VIDEO 0+ CN Ground +5PHEAD LPOW Ground LADJ* CN LPOW FB LENA* Ground HSYNC CN* HSYNC ID +5 V dc Pin no. Signal

5-4

Service Manual

System board (see System board on page 5-3) connector pins

Connector J7 USB port Pin no. 1 2 3 4 5 6 7 J8 Cover closed switch 1 2 3 J10 Fuser DC 1 2 3 4 5 6 7 8 9 10 11 J14 Signature button 1 2 J15 HVPS 1 2 3 4 5 6 7 8 input sensor 9 10 Cartridge toner wheel sensor 11 12 13 Cov Closed Ground +5 V dc NARMEDIA* Ground THERM Ground THUMP +5V dc THUMPRET EXIT SNS* +3.3 V dc I2C CLK L5 I2C DAT L5 SM Cart Ground ATSERVO TXENABLE XFR 24 V dc switched CHARGE Ground DEV Ground INPUTSENSX +5 V dc switched +5 V dc TONER WHEELX Ground Signal

Locations and connections

5-5

System board (see System board on page 5-3) connector pins

Connector J16 Ethernet port Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 J17 Parallel port J18 Front/bottom options 1 2 J20 Transport motor 1 2 3 4 5 6 7 8 9 J21 Autoconnectfront/bottom 1 2 3 4 J23 MPF pick solenoid 1 2 J24 Autocomp motor 1 2 J25 Autoconnectbottom/front 1 2 Ground +24 V dc OTC OPT BLDC_HALL 0 BLDC_HALL 1 BLDC_HALL 2 BLDC FG Ground +5 V dc switched BLDC WIND BLDC WIND 1 BLDC WIND 2 Ground +5 V dc fused Ground +24 V dc PTC OPT MPFPick* +24V dc +24 V dc AUTOCOMP* Ground +24VPTCOPT Signal

5-6

Service Manual

System board (see System board on page 5-3) connector pins

Connector J26 Paper size sensor/autocomp motor Pin no. 1 2 3 4 5 6 7 8 9 10 J27 LVPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 J28 MPF paper out 1 2 3 Signal PSIZE2 Ground PSIZE1 PSIZE3 Ground TRAY1 POUT TRAY1 PLOW* +3.3V dc ENCODER +5V dc +5 V dc +5 V dc +5 V dc Ground Ground Ground Ground Ground Ground Ground +24 V dc RAW Ground +24 V dc RAW +24 V dc RAW ZEROXING R+ +24 V dc RAW HEAT HEAT Ground L FAN DRV* MPF POUT Ground MPF LED

Locations and connections

5-7

System board (see System board on page 5-3) connector pins

Connector J30 USB hostback Pin no. 1 2 3 4 5 6 7 USB hostfront connection 1 2 3 4 5 Printhead fan 1 2 +5 V USBICN USB DI USB DI+ Ground Ground +24V dc PH FAN* Signal

Autoconnect
Connector Bottom autoconnect Pin no. 1 2 3 4 5 6 Signal (static) +24 V dc 0 V dc +5 V dc 0 V dc 0 V dc 0 V dc

Front autoconnect

1 2 3 4 5 6

0 V dc 0 V dc 0 V dc +5 V dc 0 V dc +24 V dc

5-8

Service Manual

Fuser board
Fuser Board (not a FRU) Connectors J1System board J2Narrow media sensor J3N/A J4Solenoid J5Exit sensor J6Thermistor

High voltage power supply

Connector CN1 System board CN no. 1 2 3 4 5 6 7 8 Signal Developer PWM +24 V dc Return Charge PWM +24 V dc IN TX PWM TX Enable TX CUR PWM SVRO OUT

Locations and connections

5-9

Interface card
Connector J1 J2 Pin no. A1 to B62 A1 to B62 Signal N/A N/A

USB card
Connector CN2 J2 Pin no. 1-5 Signal Signals USB signals

5-10

Service Manual

Low voltage power supply

Connector CN1 Fuser lamp AC CN pin no. 1 2 3 Signal AC fuser lamp Not used AC fuser lamp

CN2 DC output

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

+5 V dc +5 V dc Ground Ground Ground Ground +24 V dc +24 V dc Heat on +5 V dc +5 V dc Ground Ground Ground Ground +24 V dc ZC Out* +42 V dc

Locations and connections

5-11

Operator panel card (UICC #1)model 450S

Note: Part of operator panel right cover assembly. Model 450S

Operator panel card connector pinsmodel 450S

Connector J3 to touchscreen display CN pin no. 1 2 3 4 J5 Not used J7 Not used J10 to J15 on scanner control card 1 2 3 4 5 6 7 8 9 10 11 12 +24 V dc +24 V dc Ground Ground TXDTXD+ TXD232 N RXD232 N Ground Ground CLKTXCLKTX+ Signal X-DRIVE +5 V dc IN X+/Y +DRIVE Y+/X +DRIVE Y-/X +5 V dc IN

5-12

Service Manual

Operator panel card connector pinsmodel 450S (continued)

Connector J10 to J15 on scanner control card (continued) CN pin no. 13 14 15 16 17 18 J12 to touchscreen display J14 132 1 2 3 4 5 6 7 8 J15 1 2 3 4 J18 to CN1 on LCD inverter card 1 2 Signal NC TX2NC TX2+ NC TXINC TXI+ MASTER RESET N Ground Signal +5 V dc IN BUTTON ADMIN (+5 V dc default, ground when pushed) Ground Vo (contrast wheel output) Vo (contrast wheel output) Ground VEE 24 V dc VEE 24 V dc +5 V dc IN BUTTON HOME BUTTON HELP (+5 V dc default, ground when push Go) Ground +5 V dc BACKLIGHT CONTROL Ground

Locations and connections

5-13

Operator panel card (UICC #1)model 500S

Note: Part of operator panel right cover assembly. Model 500S

Operator panel card connector (UICC #1) pinsmodel 500S

Connector J3 to touchscreen display CN pin no. 1 2 3 4 J5 Not used J7 Not used 1-4 1-14 Signal X-DRIVE +5 V dc IN X+/Y +DRIVE Y+/X +DRIVE Y-/X +5 V dc IN Signal Signal

5-14

Service Manual

Operator panel card connector (UICC #1) pinsmodel 500S (continued)

Connector J10 to J15 on scanner control card CN pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 J12 to touchscreen display J13 to CN1 on inverter card 132 1 2 3 4 5 6 7 8 Signal +24 V dc +24 V dc Ground Ground TXDTXD+ TXD232 N RXD232 N Ground Ground CLKTXCLKTX+ NC TX2NC TX2+ NC TXINC TXI+ MASTER RESET N Ground Signal +12 V dc +12 V dc Ground Ground BACKLITE CONTROL PWM DIM Ground Ground

Locations and connections

5-15

LCD inverter board (IUCC #2)

Note: Part of operator panel left cover.)

Model 450S

Models 500S

Connector CN1 to J13 on operator panel card (Model 450S) CN1 to J13 on operator panel card (Model 500S)

CN pin no. 1 2 1 2 3 4 5 6 7 8

Signal +5 V dc BL Ground +12 V dc +12 V dc Ground Ground BACKLITE CONTROLLamp on/ off control PWM DIMBright adjust Ground Ground HV DO NOT MEASURE Not used Not used Not used HV DO NOT MEASURE

CN2 to touchscreen display

1 2 3 4 6

5-16

Service Manual

Scanner control card

Model 450S Model 500S

Scanner control card connector pins

Connector J1 to CN1 on flatbed interface card CN pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Signal MDC DET +25 V dc IN +25 V dc IN +25 V dc IN Ground nTOP FB nTOP ADF Ground nSTART LINE Ground MDC TXD MDC RXD Ground nADF Present nCOVER CLOSED Ground FAN ON FAN BACK Ground

Locations and connections

5-17

Scanner control card connector pins (continued)

Connector J1 to CN1 on flatbed interface card (continued) CN pin no. 20 21 22 23 24 J2 FB CCD ribbon cable J3 Not used 1-36 1 2 3 4 J4 Not used 1 2 3 4 J5 Not used 1 2 3 4 J7 To hard disk assembly (model 500S only) 2 3 4 J12 to hard disk (model 500S only) 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 1 Signal nRESET +3.3 V dc Ground Signal Signal Signal Ground VXADF RXD2 VXADF TXD2 +5 V dc Ground MDC RXD MDC TXD +5 V dc Ground VXADF RXD1 VXADF TXD1 +5 V dc +12 V dc Ground Ground +5 V dc +5 V dc Ground Signal Signal Signal Signal Signal Signal Signal Signal Signal Signal Signal Signal Signal Signal

5-18

Service Manual

Scanner control card connector pins (continued)

Connector J12 to hard disk (model 500S only) (continued) CN pin no. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 33 34 35 36 37 38 39 40 J13 to J59 on modem card 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Signal Signal Signal Ground HARD KEY Signal Signal Signal Signal Signal Signal Signal Signal Signal Ground Signal +5 V dc Ground Signal Signal Signal Signal Signal Ground +5 V dc Ground +3.3 V dc +3.3 V dc Signal Signal Signal Signal Ground Signal Signal Signal Signal Signal Signal

Locations and connections

5-19

Scanner control card connector pins (continued)

Connector J13 to J59 on modem card (continued) CN pin no. 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 J15 to operator panel card 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Signal Signal Signal Signal Signal Signal Signal Ground DSP-IRQ IO-WRITE IO-READ MOD CS Ground MOD RDY MOD PRES RESET N MASTER RESET N Ground TX1TX1+ TX2TX2+ CLKTXCLKTX+ Ground Ground UITXD UIRXD TX0TX0+ Ground Ground +24 V dc +24 V dc

5-20

Service Manual

Scanner control card connector pins (continued)

Connector J23 to CN5 on flatbed interconnect card CN pin no. C1 C2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Signal Ground Ground CCD ON POWER SAVER +24 V dc IN Ground Ground Ground Ground Ground Ground Ground Ground Signal Signal Ground Signal Signal Ground Signal SDI SEN Signal Ground Signal Signal Ground Signal Signal Signal Signal CCD CLAMP CCD RESET CCD PHRASE CCD TRANSFER CCD BW SELECT +24 V dc IN Ground

Locations and connections

5-21

Scanner control card connector pins (continued)

Connector J28ADF CCD (500S) CN pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Signal CCD DET R ADF HOME ON ADF POWER SAVER +24 V dc LAMP +24 V dc LAMP ADF CCD BW SEL Ground ADFR CCD TRANS Ground ADFR CCD PHASE 1 Ground ADFR CCD RESET Ground ADFR CCD CLAMP Ground ADFR CCD CLK Ground ADFR AFE RSAMP Ground ADFR AFE VSAMP Ground ADFR AFE D ADFR AFE D Ground ADFR AFE D ADFR AFE D Ground ADFR AFE D ADFR AFE D Ground ADFR AFE D ADFR AFE D Ground ADFR AFE SEN ADFR AFE SCK ADFR AFE SD1

5-22

Service Manual

Motor driver board

Motor drive board connector pins

Connector CN2 to ADF feed motor CN pin no. 1 2 3 4 5 6 CN3 to ADF scan motor 1 2 3 4 5 6 CN5 to pick arm solenoid 1 2 CN6 to flatbed interconnect card C1 C2 1 2 3 4 5 6 7 8 9 10 Signal A +25 V dc Na B +25 V dc VBB OUT A +25 V dc OUT nA OUT B OUT nB +25 V dc SOL ON +25 V dc Ground Ground MDC ON +25 V dc +25 V dc nTOP ADF nSTART LINE MDC TXD Ground nCOVER CLOSED OUT A OUT A

Locations and connections

5-23

Motor drive board connector pins (continued)

Connector CN6 to flatbed interface card (continued) CN pin no. 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 CN7 to cover closed and cover closing sensors 1 2 3 4 5 6 CN8 to paper tray sensor 1 2 3 4 5 6 Signal OUT B OUT B Ground nFLAT LENGTH1 nFLAT LENGTH3 Ground FAN BACK nRESET +25 V dc +25 V dc nTOP FB Ground Ground MDC RXD nADF PRESENT Ground OUT nA OUT nA OUT nB OUT nB Ground nFLAT LENGTH2 nHOME FAN ON +5 V dc Ground +5 V dc IN nCOVER CLOSING Ground +5 V dc IN nCOVER CLOSED Ground Ground ADF WIDTH1 ADF WIDTH2 Ground nADF LENGTH +5 V dc IN

5-24

Service Manual

Motor drive board connector pins (continued)

Connector CN9 to ADF exit sensor, ADF second scan sensor CN pin no. 1 2 3 4 5 6 7 8 9 CN10 to jam remove sensor, ADF paper present sensor, interval sensor, first scan sensor 1 2 3 4 5 6 7 8 9 10 11 12 Signal Ground nADF EXIT +5 V dc IN Ground +5 V dc IN n2ND SCAN Ground nADF COVER +5 V dc IN Ground nJAM REMOVE +5 V dc IN Ground nADF PRESENT +5 V dc IN Ground nADF INTERVAL +5 V dc IN Ground +5 V dc IN n1ST SCAN

Locations and connections

5-25

Flatbed interconnect card

Model 450S Model 500S

Flatbed interconnect card connector pins

Connector J1 to CN6 on ADF motor drive card Pin no. C1 C2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Signal Ground Ground MDC ON +25 V dc +25 V dc nTOP ADF nSTART LINE MDC TXD Ground nCOVER CLOSED OUT A OUT A OUT B OUT B Ground nFLAT LENGTH1 nFLAT LENGTH3 Ground FAN BACK

5-26

Service Manual

Flatbed interconnect card connector pins (continued)

Connector J1 to CN6 on ADF motor drive card Pin no. 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 J1 to CN6 on ADF motor drive card (continued) 35 36 J2 to CN2 on ADF CCD module (model 500S) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Signal nRESET +25 V dc +25 V dc nTOP FB Ground Ground MDC RXD nADF PRESENT Ground OUT nA OUT nA OUT nB OUT nB Ground nFLAT LENGTH2 nHOME FAN ON +5 V dc Ground

Locations and connections

5-27

Flatbed interconnect card connector pins (continued)

Connector CN1 to J1 on scanner control card Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 CN2 Flatbed scan motor 1 2 3 4 5 6 Signal MOC DET +25 V dc IN +25 V dc IN +25 V dc IN Ground nTOP FB nTOP ADF Ground nSTART LINE Ground MDC TXD MDC RXD Ground nADF PRESENT nCOVER CLOSED Ground FAN ON FAN BACK Ground nRESET +3.3 V dc Ground Signal Signal OUT A +25 V dc out nA OUT B +25 V dc OUT nB

5-28

Service Manual

Flatbed interconnect card connector pins (continued)

Connector CN3 Flatbed paper length sensor assembly Pin no. 1 2 3 4 5 6 7 8 9 CN4 home sensor 1 2 3 CN5 C1 C2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Signal Ground nFLAT LENGTH1 +5 V dc IN Ground nFLAT LENGTH2 +5 V dc IN Ground nFLAT LENGTH3 +5 V dc IN Ground nHOME +5 V dc IN Ground Ground CCD ON POWER SAVER +24 V dc IN Ground Ground Ground Ground Ground Ground Ground Ground Signal Signal Ground

Locations and connections

5-29

Flatbed interconnect card connector pins (continued)

Connector CN5 (continued) Pin no. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Signal Signal Signal Ground Signal SDI SEN Signal Ground Signal Signal Ground Signal Signal Signal Signal CCD CLAMP CCD RESET CCD PHASE CCD TRANSFER CCD BW SE:LECT +24 V dc IN Ground

5-30

Service Manual

Modem card
Modem card connector pins Connector
J68 on modem card Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Signal +5 V dc Ground +3.3 V dc +3.3 V dc Signal Signal Signal Signal Ground Signal Signal Signal Signal Ground Signal Signal Signal Signal Signal Signal Signal Ground DSP-IRQ IO-WRITE IO-READ MOD CS Ground MOD RDY MOD PRES RESET N

Locations and connections

5-31

5-32

Service Manual

6. Preventive maintenance
This chapter describes procedures for printer preventive maintenance. Following these recommendations can help prevent problems and maintain optimum performance.

Safety inspection guide

The purpose of this inspection guide is to aid you in identifying unsafe conditions. If any unsafe conditions exist, find out how serious the hazard could be and if you can continue before you correct the hazard. Check the following items:

Damaged, missing, or altered parts, especially in the area of the on/off switch and the power supply. Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover. Possible safety exposure from any non-Lexmark attachments.

Lubrication specifications
No requirements for this printer.

Scheduled maintenance
Maintenance kit
The operator panel displays the message 80 Scheduled Maintenance at each 300K page count interval. It is necessary to replace the fuser assembly, transfer roller, charge roll, and pick tires at this interval to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part numbers:

Maintenance kits
Description 115 V Maintenance kit 220 V Maintenance kit 100 V Maintenance kit Part number 40X0100 40X0101 40X0197

After replacing the kit, the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message. See Maintenance Page Count on page 3-25.

Preventive maintenance

6-1

Cleaning the scanner glass, cushions, and strips

1. Open the document cover. 2. Dampen a clean, lint-free cloth or cotton swab with isopropyl alcohol. 3. Clean the following with the cloth or swab: Flatbed contact glass Flatbed white cushion Front flatbed white strip Glass slit in flatbed glass holder (see step 4).
All models

4. Remove the flatbed glass holder and clean both sides of the glass slit. See Upper glass holder
removal on page 4-53. Warning: Be careful not to touch the white calibration strip (A) on the underside of the scanner flatbed glass holder.

6-2 Service Manual

5. For model 500S, remove the flatbed white cushion. See Flatbed white cushion removal on
page 4-32.

6. Press the release lever to open the lower exit guide 7. Use the cloth or swab to clean the ADF CCD glass and back ADF white strip with the cloth or swab.
Model 500S

8. Close the lower exit guide. 9. Close the document cover.

Preventive maintenance

6-3

6-4 Service Manual

7. Parts catalog How to use this parts catalog

The following legend is used in the parts catalog: Units/mach - OR Units/option Units/ kit or pkg

AsmIndex

Part number

Description

Asm-index: identifies the assembly and the item in the diagram. For example, 3-1 indicates Assembly 3
and the item number 1. Part number: identifies the unique number that identifies this FRU. Units/mach: refers to the number of units actually used in the base machine or product. Units/option: refers to the number of units used in the option and does not include the base machine. Units/kit or pkg: refers to the number of units packaged together and identified by the part number. PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet. NS: (Not shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration. NA: (Not available) in the parts description column indicates the part is shown for identification purposes only and is not available as a FRU.

Model information used in the parts catalog. Model name e-Studio 450S e-Studio 500S Configuration Network, modem Network, modem, hard disk Machine type 7002-005 7002-111 Parts catalog 005 111

Parts catalog

7-1

Assembly 1: Coversprinter (model 450S)

7-2 Service Manual

Assembly 1: Coversprinter (model 450S)

AsmIndex 11 2 3 4 5 6 7 8 Part number 40X0001 40X0469 40X0467 40X0468 40X0473 40X0471 40X0516 40X3309 Units/ mach 1 1 1 1 1 1 2 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 Description Fuser wiper cover assembly Upper sub cover assembly Upper cover assembly Upper tray cover (paper support) Right side cover Right cover assembly Counterbalance spring Upper front cover hinge assembly450S, includes: 9 40X3303 1 1 10 11 40X0493 40X3301 1 1 1 1 Operator panel frame (hinge) UICC 18-pin cable USB cable Cover open sensor Left hinge cable retainer Right hinge cable retainer Left hinge spring Right hinge spring Ground cable Screw, M3x10 (3) Screw, Sunk head (1) Operator panel right cover Dial numeric pad key Control 1Stop key Control 2Go key Control 3Clear key Hook, operator panel right assembly Compression spring LCD operator panel cap UICC #1 card assembly Screw, M3x8 (2) Screw, M3x8 (2)

Operator panel right cover assembly450S, includes:

Multipurpose tray assembly LCD mono touchscreen display assembly450S, includes: LCD lower cover Mono LCD assembly LCD frame lever LCD lever spring Core Screw, M3x8 (4) Bezel UICC #3 Home key M3x8 screws (2) Operator left cover Operator panel left hook Admin key UICC #2 card assembly Compression spring M3x18 screws (2) M3x18 screws (2)

12

40X3299

Cover bezel 450S, includes

13

40X3302

Operator panel left cover assembly450S, includes

14

40X0151

USB board assembly

Parts catalog

7-3

Assembly 1 (continued): Coversprinter (model 450S)

7-4 Service Manual

Assembly 1: Coversprinter (model 450S)

AsmIndex 115 16 17 18 NS NS NS 40X0050 40X5651 Part number 40X3304 40X0009 40X0470 40X0472 Units/ mach 1 1 1 1 5 2 1 Units/ kit or pkg 1 1 1 1 10 1 1 Description LCD (mono) touchscreen inverter card450S TLI/ID/serial number labelblank Left cover assembly Left side cover Parts packet (cable ties) (PP 40X0174) Counterbalance spring Vent cover

Parts catalog

7-5

Assembly 2: Coverprinter (model 500S)

7-6 Service Manual

Assembly 2: Coversprinter (model 500S)

AsmIndex 21 2 3 4 5 6 7 8 Part number 40X0001 40X0469 40X0467 40X0468 40X0473 40X0471 40X0516 40X0515 Units/ mach 1 1 1 1 1 1 2 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 Description Fuser wiper cover assembly Upper sub cover assembly Upper cover assembly Upper tray cover (paper support) Right side cover Right cover assembly Counterbalance spring Upper front cover hinge assembly500S, includes: 9 40X0496 1 1 10 11 12 13 14 15 16 17 18 NS NS 40X0050 40X0493 40X0494 40X0476 40X0495 40X0151 40X0497 40X0009 40X0470 40X0472 1 1 1 1 1 1 1 1 1 5 2 1 1 1 1 1 1 1 1 1 10 1 Cable, VICC 18-pin Hinge, operator panel USB cable (1) Cover open switch and cable (1) Left cable retainer (1) Right cable retainer (1) Left hinge spring (1) Right hinge spring (1) Stop button (1) Go button (1) Clear button (1) LED cap (1) Dial number pad User interface control card assembly Compression spring Operator panel right cover Operator panel right side hook

Operator panel right cover assembly500S, includes:

Multipurpose tray assembly LCD touchscreen display assembly500S Cover bezel 500S Operator panel left cover assembly500S USB board assembly LCD touchscreen inverter card TLI/ID/serial number labelblank Left cover assembly Left side cover Parts packet (cable ties) (PP 40X0174) Counterbalance spring

Parts catalog

7-7

Assembly 3: CoversADF scanner

7-8 Service Manual

Assembly 3: CoversADF scanner

AsmIndex 31 2 3 4 5 6 7 8 9 Part number 40X0450 40X3296 40X0451 40X3297 40X0452 40X0463 40X0465 40X0464 Units/ mach 1 1 1 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 1 Description Complete ADF assembly500S Complete ADF assembly450S Document tray assembly500S Document tray assembly450S ADF top cover assembly ADF scan cover ADF rear cover ADF front cover Parts packet, sensors (PP 40X0481)

Parts catalog

7-9

Assembly 4: Frame 1

7-10 Service Manual

Assembly 4: Frame 1
AsmIndex 41 2 3 4 5 6 7 8 9 40X0024 40X0026 40X0025 40X0060 40X0231 40X0285 Part number 40X0065 40X0225 Units/ mach 4 1 4 1 1 1 1 1 1 Units/ kit or pkg 1 1 4 1 1 1 1 1 1 Description Frame extension, nut plate Right side hand holder Parts packet (PP 40X0165) Right frame extension Right side frame ground contact Left frame extension External ground clip Left side hand holder Frame clip

Parts catalog

7-11

Assembly 5: Frame 2

7-12 Service Manual

Assembly 5: Frame 2
AsmIndex 51 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 NS 40X0048 40X0046 40X0049 40X0054 40X0051 40X0052 40X0058 40X0264 40X0232 40X0059 1 1 1 1 1 1 1 1 1 1 2 Part number 40X0027 40X0028 40X0030 40X0032 40X0044 Units/ mach 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Description Upper redrive deflector Upper diverter spring Redrive assembly500-sheet in/500 out Transfer deflector with brush Gear guard Parts packet (PP 40X0165) Paper switch activate spring Paper size sensing board assembly Gear release link Main fan with cable500-sheet output Standard bin level sensor Standard bin level sensor bracket Output paper level flag Standard bin level sensor cable Redrive door assembly 500 sheet Extension guide Parts packet, redrive mounting screws (P/N 40X0254)

Parts catalog

7-13

Assembly 6: Frame 3

7-14 Service Manual

Assembly 6: Frame 3
AsmIndex 61 2 3 3 4 5 6 7 8 40X0034 40X0033 40X0223 40X0036 40X0306 Part number 40X0249 40X0208 Units/ mach 1 1 1 1 1 4 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 1 Description EP DC fan assembly Blower duct Parts packet (PP 40X0165) Parts packet (PP 40X0165) Signature button contact assembly with cable Machine mounting pad HVPS/input sensor/toner sensor cable assembly Toner sensor assembly High voltage contact kit, including: 9 10 11 12 13 14 15 16 17 40X0213 40X0021 40X0040 40X0042 40X0039 40X0043 40X0209 40X0045 40X0207 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 Charge roll contact (1) Doc/TAR/Dev contact (3) PC drum contact (1) Screw (5) Screw block (4)

Tray bias assembly Cartridge holddown assembly Upper paper feed deflector Inner paper feed deflector Developer support roller Input sensor Gear #60 MPF shield ESD shield with label EP duct

Parts catalog

7-15

Assembly 7: Scanner automatic document feeder (ADF)pickup

AsmIndex 71

Part number 40X0453

Units/ mach 1

Units/ kit or pkg

Description Pickup assembly

7-16 Service Manual

Assembly 8: Scanner ADFpaper feed

AsmIndex 81

Part number 40X4656

Units/ mach 1

Units/ kit or pkg 1

Description Upper entrance guide kit, including: ASeparator roller with hub BTorque limiter CUpper entrance guide DSub ADF separator guide ESnap ring

2 3

40X4658 40X4657

1 1

1 1

Sub ADF separator guide Entrance guide

Parts catalog

7-17

Assembly 9: Scanner ADFlower exit guide assembly

AsmIndex 91 1 2

Part number 40X0460 40X3311 40X0458

Units/ mach 1 1 1

Units/ kit or pkg 1 1 1

Description Lower exit guide assembly500S Lower exit guide assembly450S ADF CCD module assembly500S only

7-18 Service Manual

Assembly 10: Scanner ADFmotors and belts

AsmIndex 101

Part number 40X0482

Units/ mach 1

Units/ kit or pkg 1

Description Belts, including: ATiming belt 52M194 BTiming belt 52M172 CTiming belt motor 52M292 DTiming belt second transport 52M152 ETiming belt first transport 52M132 Note: Belt P/N stamped on belt. FTiming belt knob 52M172

2 3

40X0461 40X0462

1 1

1 1

Feed motor (ADF feed) ADF scan motor assembly

Parts catalog

7-19

Assembly 11: Scanner ADFsensors

7-20 Service Manual

Assembly 11: ADFsensors

AsmIndex 111 2 Part number 40X0456 40X0481 Units/ mach 1 1 Units/ kit or pkg 1 4 Description Pickup arm assembly solenoid Parts packet, sensors ASecond scan sensor BPaper present CInterval sensor DFirst scan sensor EADF top cover open FFlatbed cover open GJam access door Note: There are four different sensors in the parts packet, some of the same sensors are used in different locations. 3 40X0486 1 1 Motor driver card

Parts catalog

7-21

Assembly 12: Scannerflatbed

500S

450S

7-22 Service Manual

Assembly 12: Scannerflatbed

AsmIndex 121 1 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 Part number 40X3298 40X0457 40X0483 40X0466 40X0475 40X0513 40X0514 40X0478 40X3312 40X0485 40X0490 40X0479 40X0480 40X0491 40X0491 40X0474 40X0481 40X0487 40X0484 Units/ mach 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Complete flatbed scanner assembly450S Complete flatbed scanner assembly500S Flatbed contact glass Flatbed white cushion Scan cover Flatbed cover closed actuator Flatbed cover closing actuator Flatbed CCD module assembly Flatbed interconnect card assembly450S Flatbed interconnect card assembly500S Belt tension spring Flatbed CCD drive belt Flatbed scan motor, including flatbed scan motor to flatbed interconnect card cable Flatbed paper size sensor assembly (assembly includes 3 sensors)500S Flatbed paper size sensor assembly (assembly includes 3 sensors but only one sensor is required)450S Front cover Parts packet, sensors (home sensor) Flatbed CCD ribbon cable Glass holder assembly

Parts catalog

7-23

Assembly 13: Printhead

AsmIndex 131 2 3

Part number 40X0061 40X0062

Units/ mach 1 1

Units/ kit or pkg 1 1

Description Laser printhead cable assembly Parts packet (PP 40X0165) (printhead mounting screw) Printhead assembly (includes all cables) CAUTION The printhead is not a serviceable FRU. Do not disassemble the printhead.

7-24 Service Manual

Assembly 14: Paper feedautocompensator

AsmIndex 141 2

Part number 40X0066 40X0069

Units/ mach 1 1

Units/ kit or pkg 1 1

Description Pick arm assembly500-sheet Parts packet, bellcrank assembly for500-sheet tray Bellcrank (1) Spring (1)

3 4 5 6 7

40X0070 40X0072 40X0215 40X0074

2 1 1 1

2 1 1 1

Pick tires, pick roll assembly Paper out flag500-sheet tray Paper low/out sensor card assembly, 500-sheet Parts packet (PP 40X0165) (hanger) Paper size/autocompensator cable

Parts catalog

7-25

Assembly 15: Paper feedmultipurpose feeder

7-26 Service Manual

Assembly 15: Paper feedmultipurpose feeder

AsmIndex 151 2 3 4 5 5 5 NS Part number 40X0079 40X0310 40X0076 40X0077 Units/ mach 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 Description Multipurpose feeder lower deflector assembly Multipurpose feeder pick arm assembly with solenoid Pick roll assembly Multipurpose feeder paper out flag Parts packet (PP 40X0165) (lower deflector mounting screw, 8 mm) Parts packet (PP 40X0165) (lower deflector mounting screw, 12 mm) Parts packet (PP 40X0165) (frame mounting screw) Parts packet (PP 40X0165) (pick roll shaft clip)

Parts catalog

7-27

Assembly 16: Paper feedalignment

7-28 Service Manual

Assembly 16: Paper feedalignment

AsmIndex 161 2 3 4 40X0085 40X0086 1 1 Part number 40X0084 Units/ mach 1 Units/ kit or pkg 1 1 1 1 Description Paper feed alignment assembly paper feed Parts packet (PP 40X0165) (clip ref ground mounting screw) Reference ground clip Parts packet (reference adjust) Screw, paper reference adjust (1) Washer, paper reference adjust (1) Nut, paper reference adjust (1) NS 1 1 Parts packet (PP 40X0165) (alignment asm mounting screw)

Parts catalog

7-29

Assembly 17: Integrated 500-sheet paper tray

7-30 Service Manual

Assembly 17: Integrated 500-sheet paper tray

AsmIndex 171 2 3 4 5 6 7 Part number 40X0098 40X0099 40X0182 40X0103 40X0183 40X0105 40X0106 Units/ mach 1 1 4 1 1 2 1 Units/ kit or pkg 1 1 1 1 1 1 1 Description Tray assembly500-sheet tray Side restraint Wear strip Pass thru plate500-sheet tray Wear plate500-sheet tray Restraint pad Back restraint

Parts catalog

7-31

Assembly 18: DrivesMain drive and developer drive

7-32 Service Manual

Assembly 18: DrivesMain drive and developer drive

AsmIndex 181 2 3 4 Part number 40X0107 40X0111 40X0112 40X0113 Units/ mach 1 1 1 1 Units/ kit or pkg 1 1 1 1 Description Gearbox with motor Power takeoff shaft500-sheet Power takeoff shaft spring Bevel gear with grease packet and washer 5 6 40X0114 40X0115 1 1 Bevel gear (1) Instruction sheet (1) Grease packet (1) washer (1)

Developer drive assembly Parts packet, developer drive Developer drive shaft (1) shaft, coupler gear #55 (1)

7 NS

3 4

Parts packet (PP 40X0165) (developer drive ground screw) Parts packet (PP 40X0165) (gearbox mounting screw)

Parts catalog

7-33

Assembly 19: Hot roll fuser

7-34 Service Manual

Assembly 19: Hot roll fuser

AsmIndex 191 1 1 2 3 3 4 Part number 40X2592 40X2591 40X2590 40X0120 40X0122 40X0123 40X0121 Units/ mach 1 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 Description Fuser assembly w/115 V lamp Fuser assembly w/100 V lamp Fuser assembly w/220 V lamp Fuser wiper cavity cover Fuser lamp, 115V Fuser lamp, 220V Fuser cover assembly kit, including: Thermistor (1) Thermostat (1) Left and right fuser lamp contact assemblies (1) 5 6 40X0239 1 Parts packet (fuser mounting screw) (PP 40X0254) Exit sensor flag/spring kit, including: Spring (1) Flag (1) 7 8 9 10 11 40X0125 40X0230 40X0238 1 1 1 1 1 12 13 NS 40X0124 40X0229 40X0226 1 1 1 1 1 1 1 1 40X0236 1 1 Exit/narrow media sensor cover Parts packet (PP 40X0165) Exit sensor Exit sensor cable Narrow media flag/spring kit, including: Spring Flag Narrow media sensor Narrow media sensor cable Fuser AC to fuser lamp cable

Parts catalog

7-35

Assembly 20: Transfer/charging

7-36 Service Manual

Assembly 20: Transfer/charging

AsmIndex 201 2 3 4 5 6 7 8 9 NS NS Part number 40X0126 40X0127 40X0129 40X0130 40X0131 40X0132 40X0133 40X0134 40X0135 1 1 1 1 1 1 1 Units/ mach Units/ kit or pkg 1 2 1 1 1 1 1 1 1 1 1 Description Parts kit, charge roll link asm, left side Charge roll assembly, dual Parts kit, right side charge roll link assembly Transfer roll assembly Transfer roll assembly right arm Transfer roll right spring Transfer pivot shaft Transfer roll left spring Transfer roll left arm Parts packet (PP 40X0165) (charge roll screw) Parts packet (PP 40X0165) (C-clip, pivot shaft)

Parts catalog

7-37

Assembly 21: Electronicspower supplies

7-38 Service Manual

Assembly 21: Electronicspower supplies

AsmIndex 211 1 2 Part number 40X4243 40X4244 40X0260 Units/ mach 1 1 1 Units/ kit or pkg 1 1 1 Description LVPS/AIO115 V ac LVPS/AIO220 V ac Power cord set (8 ft right angle, 13 amp)United States, Canada, Caribbean countries, Colombia, Costa Rica, Dominican Republic, El Salvador, Equator, Guatemala, Honduras, Mexico, Nicaragua, Panama, Puerto Rico, Saudi Arabia, Venezuela, and Virgin Islands Power cord set (8 ft right angle)Bolivia and Peru Power cord set (8 ft right angle)Argentina Power cord set (8 ft right angle)Chile, Uruguay Power cord set (8 ft right angle)Arabic, Austria, Belgium, Bluemark, CIS, Czechoslovakia, Denmark, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Medmark, (1 and 2), Netherlands, Norway, Paraguay, Poland, Portugal, Russia, Slavic countries, Spain, Sweden, Turkey, and UK. Power cord set (8 ft right angle)Anguilla (UK), Antigua and Barbuda, Bahrain, Botswana, Burma (Myanmar), Channel Islands, Cyprus, Dominica, Falkland Islands, Gambia, Ghana, Gibraltar, Grenada, Guyana, Hong Kong, Iraq, Ireland, Isle of Man, Jordan, Kenya, Kuwait, Lebanon, Liberia, Malawi, Malaysia, Malta, Mauritius, Montserrat, Nigeria, Oman, Pakistan, Pitcairn Island (UK), Qatar, Scotland, Seychelles, Sierra Leone, Singapore, St. Kitts and Nevis, St. Lucia, St. Vincent and Grenadines, Sudan, Tanzania, Trinidad and Tobago, Uganda, United Arab Emirates, United Kingdom, Vanuatu, Wales, Yemen, Zambia, Zimbabwe. Power cord set (6 ft right angle)Brazil Power cord set (8 ft straight)AS/NZS Power cord set (8 ft straight)Hong Kong Power cord set (8 ft right angle)Japan Power cord set (6 ft straight)Korea Power cord set (8 ft straight)PRC Power cord set (6 ft right angle)Taiwan Power cord set (8 ft right angle)Denmark, Norway, and Sweden Power cord set (8 ft right angle)Israel Power cord set (8 ft right angle)Botswana, Lesotho, Namibia, Pakistan, and South Africa Power cord set (8 ft right angle)Switzerland High voltage power supply Parts packet (PP 40X0165) 1 Front cable harness (HVPS/input sensor/toner sensor)

2 2 2 2

40X0256 40X0255 40X0257 40X0258

1 1 1 1

1 1 1 1

40X0293

2 2 2 2 2 2 2 2 2 2 2 3 4 5

40X0259 40X0301 40X0271 40X0272 40X0280 40X0303 40X0281 40X0294 40X0295 40X0304 40X0305 40X4275 40X0223

1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1

Parts catalog

7-39

Assembly 22: Electronicscard assemblies

450S

500S

7-40 Service Manual

Assembly 22: Electronicscard assemblies

AsmIndex 221 1 2 3 4 5 6 6 7 7 7 7 7 7 8 9 NS NS Part number 40X3305 40X0498 40X0509 40X0489 40X0520 40X0510 40X3310 40X2722 40X3477 40X2792 40X2529 40X2793 40X3479 40X4178 40X0519 40X0507 40X3478 40X4179 Units/ mach 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Scanner control card450S Scanner control card500S Hard disk IDE 50-pin cable500S Hard disk assembly500S Interface card assembly Hard disk 4-pin power cable500S System board assembly450S (Board ID M010 6030) System board assembly (network)500S (Board ID M010 6000) Bar code card assembly450S Bar code card assembly500S IPDS SCS/TNe card assembly500S PRESCRIBE card assembly500S PrintCryption card assembly450S PrintCryption card assembly500S Modem card assembly Modem 30-pin cable Forms card assembly450S Forms card assembly500S

Note: The system board has a label with an board ID and barcode. Use the first eight numbers to identify the board with the part number in the table above:

Parts catalog

7-41

Assembly 23: Electronicsshields

AsmIndex 231 2 2 2 3 4 5

Part number 40X0150

Units/ mach 1

Units/ kit or pkg 1

Description Outer shield Parts packet (PP 40X0165) (INA cover mounting screw) Parts packet (PP 40X0165) (outer shield mounting screw) Parts packet (PP 40X0165) (inner shield mounting screw)

40X0149 40X0153 40X0152

1 1 1

1 1 1

Inner shield assembly INA flat cover (blank) Ethernet shield (blank)

7-42 Service Manual

Assembly 24: Cabling diagram 1

AsmIndex 241 2 3

Part number 40X0223 40X0160 40X0264

Units/ mach 1 1 1

Units/ kit or pkg 1 1 1

Description HVPS/input sensor/toner sensor cable assembly MPF sensor cable Standard bin level sensor cable

Parts catalog

7-43

Assembly 25: Cabling diagram 2

AsmIndex 251 2 3

Part number 40X0061 40X0074 40X0046

Units/ mach 1 1 1

Units/ kit or pkg 1 1 1

Description Laser printhead cable assembly Paper size/autocompensator cable Paper size sensing board assembly

7-44 Service Manual

Assembly 26: Cabling diagram 3

AsmIndex 261 2 3 4

Part number 40X0034 40X0156 40X0223 40X0224

Units/ mach 1 1 1 1

Units/ kit or pkg 1 1 1 1

Description Signature button contact assembly with cable Bottom/front autoconnect cable assembly HVPS/input sensor/toner sensor cable assembly LVPS to system board cable assembly

Parts catalog

7-45

Assembly 27: Cabling diagram 4model 450S

7-46 Service Manual

Assembly 27: Cabling diagram 4model 450S

AsmIndex 271 Part number 40X3309 Units/ mach 1 Units/ kit or pkg 1 Description Upper front cover hinge assembly450S, includes 2 3 4 40X0162 40X0163 40X0226 1 1 1 1 1 1 1AOperator panel to LCD Inverter card cable (2-pin) 1BOperator panel card to UICC #2 card cable (8-pin) 1CUSB cable (1) 1DCover open switch/cable from system board 1ELCD display to operator panel card cable (14-pin ribbon) 1FOperator panel cable from SCC 1GOperator panel card to bezel card cable (4-pin) 1HLCD display to operator panel card cable (4-pin) 1JLCD display to LCD inverter card cable (2-pin)

System board to fuser board cable assembly Fuser AC lamp to LVPS cable assembly Fuser connector (fuser AC to fuser lamp)

Parts catalog

7-47

Assembly 28: Cabling diagram 4model 500S

7-48 Service Manual

Assembly 28: Cabling diagram 4model 500S

AsmIndex 281 Part number 40X0515 Units/ mach 1 Units/ kit or pkg 1 Description Upper front cover hinge assembly500S, includes: 1AUSB cable (1) 1BCover open switch/cable (1) 1COperator panel cable to SCC card (1) See full description of upper front cover hinge assembly on page 7-7. 2 3 4 5 6 40X0511 40X0512 40X0162 40X0163 40X0226 1 1 1 1 1 1 1 1 1 1 Inverter 32-pin cable (operator panel card to LCD inverter card) 32-pin cable (LCD display to operator panel cable) System board to fuser board cable assembly Fuser AC lamp to LVPS cable assembly Fuser connector (fuser AC to fuser lamp)

Parts catalog

7-49

Assembly 29: Cabling diagram 5

3

3 1 2 3 4

7-50 Service Manual

Assembly 29: Cabling diagram 5

AsmIndex 291 2 3 4 5 Part number 40X0310 40X0159 40X0249 40X0054 40X0161 Units/ mach 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 Description Multipurpose feeder pick arm assembly with solenoid Main drive motor cable assembly EP DC fan assembly Main fan with cable, 500-sheet output Ground cable

Parts catalog

7-51

Assembly 30: Cabling diagram 6model 450S

7-52 Service Manual

Assembly 30: Cabling diagram 6model 450S

AsmIndex 301 2 3 4 5 6 7 8 Part number 40X0491 40X0481 40X0487 40X0507 NA NA 40X0480 NA Units/ mach 1 1 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 Description Flatbed paper size sensor assembly (3 sensors are included in the assembly, model 450S uses only one) Parts packet, sensors (home sensor) Flatbed CCD ribbon cable Modem 30-pin cable Flatbed interconnect card (CN1) to SCC card cable (J15) (NOT AVAILABLE AS A FRU) Flatbed interconnect card (CN4) to home sensor cable (NOT AVAILABLE AS A FRU) Flatbed scan motor, including flatbed scan motor to flatbed interconnect card cable Flatbed paper size sensor to interconnect card cable (CN3) (NOT AVAILABLE AS A FRU)

Parts catalog

7-53

Assembly 31: Cabling diagram 6model 500S

7-54 Service Manual

Assembly 31: Cabling diagram 6model 500S

AsmIndex 311 2 3 4 5 6 7 8 9 10 11 Part number 40X0491 NA 40X0481 40X0487 40X0509 40X0510 40X0507 NA NA NA 40X0480 Units/ mach 1 1 1 1 1 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 1 1 1 Description Flatbed paper size sensor assembly (3 sensors are included in the assembly, model 450S uses only one) Flatbed paper size sensor cable to flatbed interconnect card (CN3) (NOT AVAILABLE AS A FRU) Parts packet, sensors (home sensor) Flatbed CCD ribbon cable Hard disk IDE 50-pin cable500S Hard disk 4-pin power cable500S Modem 30-pin cable Scanner control card (J1) to flatbed interconnect card (CN1) cable (NOT AVAILABLE AS A FRU) Scanner control card (J28) to flatbed interconnect card (CN5) (NOT AVAILABLE AS A FRU) Home sensor to flatbed interconnect card (Cn4) (NOT AVAILABLE AS A FRU) Flatbed scan motor, including scan motor

Parts catalog

7-55

Assembly 32: Cabling diagram 7

4 1A 2

1B

1C

1D

AsmIndex 321

Part number 40X0481

Units/ mach 1

Units/ kit or pkg 1

Description Parts packet, sensors ASecond scan sensor BJam access door sensor CFirst scan sensor DInterval sensor

2 3 4

40X0456 40X0486 NA

1 1 1

1 1 1

Pickup arm assembly solenoid Motor driver card Paper present sensor cable (NOT AVAILABLE AS A FRU)

7-56 Service Manual

Assembly 33: Cabling diagram 8model 450S

AsmIndex 331

Part number 40X0481

Units/ mach 1

Units/ kit or pkg 1

Description Parts packet, sensors AADF top cover open sensor BFirst scan sensor CFlatbed cover closed sensors (cover closing, cover closed) DADF paper length sensor

2 3 4 5 6

NA 40X0506 NA N/A N/A

1 1 1 1 1

1 1 1 1 1

Feed motor cable (NOT AVAILABLE AS A FRU) MDC to flatbed interconnect card 36-pin cable Flatbed cover open sensor cable (NOT AVAILABLE AS A FRU) Transport motor cable (NOT AVAILABLE AS A FRU) Paper length sensor cable, includes paper width sensor assemblyX644e/ X646e

Parts catalog

7-57

Assembly 34: Cabling diagram 8model 500S

AsmIndex 341

Part number 40X0481

Units/ mach 1

Units/ kit or pkg 1

Description Parts packet, sensors AADF top cover open sensor BFirst scan sensor CFlatbed cover closed sensors (cover closing, cover closed) DADF paper length sensor

2 3 4 5 6 7

NA 40X0502 40X0506 NA N/A N/A

1 1 1 1 1 1

1 1 1 1 1 1

Feed motor cable (NOT AVAILABLE AS A FRU) ADF CCD to flatbed interconnect card 36-pin cable500S MDC to flatbed interconnect card 36-pin cable Flatbed cover open sensor cable (NOT AVAILABLE AS A FRU) Transport motor cable (NOT AVAILABLE AS A FRU) Paper length sensor cable, includes paper width sensor assembly500S

7-58 Service Manual

Assembly 35: Optional 250-sheet paper drawer

AsmIndex 351 2 3 4 5 5 6 7 8 9 10 11 12 13 14

Part number 40X3230 99A0063 56P4129

Units/ option 1 1 1 1 3 4

Units/ kit or pkg 1 1 1 1 3 4 1 1 1 2 1 1 1 1 1

Description 250-sheet paper drawer, complete assembly Parts packet, screws (PP 99A0263) (switch spring) Switch activate spring Paper out arm250-sheet Parts packet, screws (PP 99A0263) (auto comp mounting) Parts packet, screws (PP 99A0263) Pick arm assembly Bellcrank250-sheet paper tray Bellcrank spring250-sheet paper tray Pick roll assembly Bin low sensor with cable Option pass thru sensor Drive shaft250-sheet Power takeoff spring Base assembly

40X3232 56P1228 99A1929 40X0070 40X3234 40X3233 99A0272 99A0275 40X3237

1 1 2 2 1 1 1 1 1

Parts catalog

7-59

Assembly 36: Optional 250-sheet paper tray

AsmIndex 361 2 3 4 5 6 7

Part number 40X3231 40X3235 56P1279 56P4230 99A0121 99A0120 40X3236

Units/ option 1 1 1 1 1 1 1

Units/ kit or pkg 1 1 4 1 1 2 1

Description Tray assembly, option250-sheet Side restraint250-sheet tray Wear strips Clip250 sheet pass thru Plate250-sheet tray wear Restraint pad Back restraint250-sheet tray

7-60 Service Manual

Assembly 37: Optional 500-sheet paper drawer

AsmIndex 371 2 3 4 5 6 7 8 9 10 11 12 13 14

Part number 40X3243 40X3246 56P1228 56P2540 40X0070 40X3233 99A0275 99A0447 40X3234 40X3247 56P4145 99A0063

Units/ option 1 3 1 1 1 1 1 1 1 1 1 1 1 1

Units/ kit or pkg 1 3 1 1 1 2 1 1 1 1 1 1 1 1

Description Drawer assembly, complete500-sheet Parts packet, screws (PP 99A0263) (auto comp mounting screw) Pick arm assembly500 sheet Bellcrank spring arm Bellcrank spring500-sheet option tray Pick roll assembly Option pass thru sensor Power takeoff spring Drive shaft500-sheet Bin low sensor with cable Base assembly, 500-sheet Paper out arm500-sheet drawer Switch activate spring Parts packet, screws (PP 99A0263)

Parts catalog

7-61

Assembly 38: Optional 500-sheet paper tray

AsmIndex 381 2 3 4 5 6 7

Part number 56P4150 56P4137 99A0292 56P4196 56P4195 99A0120 56P4147

Units/ option 1 1 1 1 1 1 1

Units/ kit or pkg 1 1 4 1 1 2 1

Description Complete tray assembly500-sheet Side restraint500-sheet tray Wear strips Pass thru plate Plate500 sheet wear Restraint pad Back restraint500-sheet tray

7-62 Service Manual

Assembly 39: Duplex option

AsmIndex 391

Part number 56P4102

Units/ option 1

Units/ kit or pkg 1

Description Duplex assembly500-sheet

Parts catalog

7-63

Assembly 40: Envelope feeder

7-64 Service Manual

Assembly 40: Envelope feeder

AsmIndex 401 Part number 40X3248 Units/ option 1 Units/ kit or pkg 1 Description Complete envelope option

Parts catalog

7-65

Assembly 41: High-capacity feeder 1

7-66 Service Manual

Assembly 41: High capacity feeder 1

AsmIndex 411 2 3 4 5 6 7 8 9 10 40X3252 99A0658 Part number 40X3249 99A1818 99A0681 40X3254 56P4157 Units/ option 1 1 4 1 1 4 4 4 1 2 Units/ kit or pkg 1 1 1 1 2 1 1 1 1 2 Description Complete option assembly (A4) Wear dimple strip Wear strip Front door assembly Door hinge Parts packet, nuts (PP 99A0676) (6-32 hinge mounting nut) Parts packet, washers (PP 99A0677) (hinge mounting flat washer) Parts packet, washers (PP 99A0677) (hinge mounting star washer) 2000-sheet option control card assembly Door magnet

Parts catalog

7-67

Assembly 42: High-capacity feeder 2

AsmIndex 421 2 3 4

Part number 99A0654 40X3262 40X2669

Units/ option 1 1 1

Units/ kit or pkg 1 1 1

Description Paper low switch Parts packet, nuts (PP 99A0676) AC external jumper cord Power supply board

7-68 Service Manual

Assembly 43: High-capacity feeder 3

AsmIndex 431 2

Part number 99A0275 99A0272

Units/ option 1 1

Units/ kit or pkg 1 1

Description Power takeoff spring Drive shaft250-sheet

Parts catalog

7-69

Assembly 44: High-capacity feeder 4

AsmIndex 441 2 3 4

Part number 40X3255 40X0070 40X3233

Units/ option 3 1 2 1

Units/ kit or pkg 1 2 1

Description Parts packet, screws (PP 99A0263) (auto comp assembly mounting screw) Pick arm assembly2000-sheet Pick roll assembly Option pass thru sensor

7-70 Service Manual

Assembly 45: Options

AsmIndex NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS Part number 40X1508 40X1509 40X1510 40X1564 40X1455 40X3477 40X4181 40X3479 40X4178 40X4180 40X1376 40X1377 40X1378 40X1562 40X0291 40X0290 40X2529 56P4116 40X3478 40X4179 40X1513 40X1514 40X1515 40X1512 40X0179 7375947 40X0499 Units/ option 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Units/ kit or pkg 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description 128MB memory option 256MB memory option 512MB memory option 32MB Flash card 64MB Flash card Bar code card assembly450S Bar code card assembly500S PrintCryption card assembly450S PrintCryption card assembly500S PRESCRIBE card assembly500S MarkNet 8020 Gigabit Ethernet MarkNet 8030 Fiber Ethernet MarkNet 8050 wireless print server, 802.11g, US MarkNet 8050 wireless print server, 802.11g, non-US Parallel 1284-B interface card RS232C serial interface card IPDS SCS/TNe card assembly500S Universal adjustable tray assembly400-sheet Forms card assembly450S Forms card assembly500S Simplified Chinese font card Traditional Chinese font card Korean font card Japanese font card Nyogel 744 grease packet Relocation kit Screws, parts packet

Parts catalog

7-71

7-72 Service Manual

Index

Numerics
250-sheet paper drawer, option 7-59 250-sheet paper tray, option parts catalog 7-60 service check 2-147 2xx paper jam and paper handing errors 2-57 500-sheet paper drawer, option 7-61 500-sheet paper tray 7-30 500-sheet paper tray, option parts catalog 7-62 service check 2-147 80 scheduled maintenance 6-1 8xx Service error codes 2-13 900.xx error code service check 2-118 950.00 through 950.29 EPROM mismatch failure 2-120 950.30 through 950.60 EPROM mismatch failure 2-121 9xx Service error codes 2-14

C
cable diagrams 7-43 , 7-44 , 7-45, 7-46, 7-48, 7-50 cabling diagrams 7-52 , 7-56, 7-57 CACHE Test 3-9 Configuration ID 3-19 configuration menu accessing 3-1, 3-24 ADF Edge Erase 3-29 Automatic Scanner Registration 3-30 available menus 3-24 Disk Encryption 3-32 Energy Conserve 3-28 Envelope Prompts 3-32 EVENT LOG (print only) 3-31 Factory Defaults 3-28 FB Edge Erase 3-30 Font Sharpening 3-34 Format Fax Storage 3-29 Jobs On Disk 3-32 Key Repeat Initial Delay 3-35 Key Repeat Rate 3-35 LES Applications 3-34 Maintenance Page Count 3-25 Min Copy Memory 3-29 Panel Menus 3-27 Paper Prompts 3-31 PPDS Emulation 3-27 Print Quality Pages 3-26 Require Standby 3-34 Reset Maintenance Counter 3-25 SIZE SENSING 3-26 Wipe Disk 3-33 Wiper Message 3-35 configurations, models 1-1, 1-2, 7-1 connector locations autoconnectbottom 5-8 autoconnectfront 5-8 connectors flatbed interconnect card 5-26 fuser board 5-9 high voltage power supply (HVPS) 5-9 interface card 5-10 LCD inverter board (IUCC #2) 5-16 low voltage power supply (LVPS) 5-11 modem card 5-31 motor driver board 5-23 operator panel card (UICC #1)model 450S 5-12 operator panel card (UICC #1)model 500S

A
acronyms 1-18 adjustments fuser solenoid 4-2 gap adjustment 4-2 paper alignment assembly 4-3 printhead assembly 4-2 scanner registration 4-4 alignment assembly adjustment 4-3 parts catalog 7-28 removal 4-122 ASIC Test 3-23 autocompensator, integrated tray parts catalog 7-25 pick roll installation 4-106 removal 4-103 autoconnect connectors, bottom 5-8 autoconnect connectors, front 5-8 automatic document feeder (ADF) parts catalog 7-17, 7-18, 7-19, 7-20 , 7-57 , 7-58 removals 4-6 sensor locations 5-2

B
barcode, system board 7-41 bevel gear installation 4-76 removal 4-75 blower duct 7-15 Button Test 3-8 buttons accessing service menus 3-1 Button Test 3-8 upper front cover including buttons 7-7 upper front panel button kit 7-7

5-14
scanner control card 5-17 system board 5-3 USB card 5-10

Index

I-1

contrast control 2-149 cover closed switch 2-125

D
defaults EP defaults 3-20 factory defaults 3-28 US/Non-US defaults 3-17 deflector inner paper deflector assembly 4-101 MPF lower paper deflector 4-117 upper paper deflector assembly 4-138 developer drive assembly parts 7-32 removal 4-77 developer drive coupler kit 4-78 diagnostics menu accessing 3-1 available tests 3-2 BASE SENSOR TEST 3-15 DEVICE TESTS Disk Test/Clean 3-16 Flash Test 3-17 Quick Disk Test 3-16 DUPLEX TESTS Duplex Feed 1 3-13 Duplex Feed 2 3-13 Motor Test 3-12 Quick Test 3-11 Sensor Test 3-12 Top Margin 3-11 EP SETUP Charge Roll 3-21 EP Defaults 3-20 Fuser Page Count 3-20 Fuser Temp 3-20 Gap Adjust 3-21 Print Contrast 3-21 Transfer 3-21 Warm Up Time 3-20 EVENT LOG Clear Log 3-22 Display Log 3-21 Print Log 3-22 exiting 3-4 HARDWARE TESTS Button Test 3-8 CACHE Test 3-9 DRAM Test 3-9 Panel Test 3-8 parallel wrap tests 3-10 serial wrap tests 3-10 INPUT TRAY TESTS Feed Test 3-13 Sensor Test 3-14 OUTPUT BIN TESTS Feed Test 3-14 Sensor Tests 3-15

PRINT TESTS input source 3-7 Prt Quality Pgs 3-7 PRINTER SETUP Configuration ID 3-19 Defaults 3-17 Edge to Edge 3-19 engine settings 3-18 Envelope Enhance 3-18 Model Name 3-18 Page Count 3-18 Par x Strobe Adj 3-19 Perm Page Count 3-18 Serial Number 3-18 REGISTRATION 3-5 Quick Test 3-6 SCANNER TESTS ASIC Test 3-23 Feed Test 3-23 Scanner Manual Registration 3-23 Sensor Tests 3-23 dimensions 1-6 Disk Encryption 3-32 DRAM Test 3-9 duplex option parts catalog 7-63 service check 2-127 duplex tests Duplex Feed 1 3-13 Duplex Feed 2 3-13 Motor Test 3-12 Quick Test 3-11 Sensor Test 3-12 Top Margin 3-11

E
Edge to Edge 3-19 Energy Conserve 3-28 Engine Setting 3-18 Envelope Enhance 3-18 envelope feeder parts catalog 7-64 service check 2-129 Envelope Prompts 3-32 EP duct 7-15 EPROM mismatch failure 2-120, 2-121 error codes, service 2-13 ESD cover 4-78 ESD-sensitive parts 4-1 event log clear log (diagnostics menu) 3-22 display log (diagnostics mode) 3-21 print log (configuration menu) 3-31 print log (diagnostics menu) 3-22

I-2 Service Manual

F
fans cartridge fan 2-119 EP fan 7-15 main fan 2-119, 4-111 Feed Test (scanner) 3-23 flag fuser exit sensor flag and spring 4-83 fuser narrow media flag and spring 4-90 paper bin full sensor 4-124 Flash Test 3-17 flatbed interconnect card connectors 5-26 parts catalog 7-22 removal 4-33 flatbed scanner parts catalog 7-22, 7-52, 7-54 removals 4-6 sensor locations 5-1 flatbed white cushion, removal 4-32 Font Sharpening 3-34 Format Fax Storage 3-29 frame extensions 4-73 frames, parts catalog 7-10, 7-12 , 7-14 fuser connectors 5-9 installation 4-80 parts catalog 7-34 removals 4-79 service check 2-132 fuser board 5-9 fuser cover 4-95 fuser exit sensor flag and spring removal 4-83 parts catalog 7-35 removal 4-82 service check 2-138 fuser lamp parts catalog 7-35 removal 4-86 fuser narrow media sensor flag and spring 4-90 flag and spring parts catalog 7-35 flag and spring removal 4-90 parts catalog 7-35 service check 2-139 fuser solenoid adjustment 4-2 service check 2-140 fuser to LVPS AC cable removal 4-92 fuser transfer plate removal 4-97 fuser wiper cover assembly parts catalog 7-3, 7-7 removal 4-54

H
handle left cover 4-72 , 7-11 right cover 4-72 , 7-11 hard disk parts catalog 7-40 removal 4-44 Help button, service check 2-154 high voltage power supply (HVPS) connectors 5-9 parts catalog 7-38 removal 4-99 high-capacity feeder service check 2-141 high-capacity input tray (HCIT) options 1-3 parts catalog 7-66, 7-68, 7-69, 7-70 service check 2-141 Home button, service check 2-154 Home screen 2-4

I
inner paper deflector removal 4-101 inner shield parts catalog 7-42 removalmodel 450S 4-130 removalmodel 500S 4-131 input sensor removal 4-102 input sensor tray tests 3-14 input source tests 3-7 input tray feed test 3-13 installation bevel gear 4-76 fuser assembly 4-80 fuser exit sensor 4-82 fuser exit sensor spring 4-84 fuser narrow media sensor 4-89 fuser narrow media spring replacement 4-90 pick roll assembly (integrated tray autocompensator)

4-106
integrated tray autocompensator assembly parts catalog 7-25 removal 4-103 interface card connectors 5-10 parts catalog 7-40 removal 4-107 service check 2-148

J
jams paper path 3-39 Jobs On Disk 3-32

K
Key Repeat Initial Delay 3-35 Key Repeat Rate 3-35 keypad 2-3

G
gap adjustment 3-21 , 4-2 gear release link removal 4-98

Index

I-3

L
lamp, fuser 4-86 LCD inverter board connectors 5-16 left cover handle holder removal 4-72 LES Applications 3-34 Lexmark Embedded Solution 3-34 locations ADF sensors 5-2 flatbed sensors 5-1 low voltage power supply (LVPS) connectors 5-11 parts catalog 7-38 removal 4-109 lower front cover assembly removal 4-71 lower paper deflector, MPF 4-117 lubrication specifications 6-1

modem card connectors 5-31 parts catalog 7-40 status messages 2-40 motor driver board, connectors 5-23 MPF arm assembly 4-116 MPF lower paper deflector 4-117 MPF solenoid assembly 4-119 multipurpose feeder parts catalog 7-26 removal 4-71

N
narrow media sensor See fuser narrow media sensor numeric keypad 2-3

O
operator panel Button Test 3-8 description 2-2 LCD inverter board 5-16 operator panel card (UICC #1), model 450S 5-12 operator panel card, model 500S 5-14 Panel Test 3-8 right cover assembly service check 2-154 upper front cover 7-7 USB card 5-10 options descriptions 1-3 parts catalog 7-71 service checks 2-155 outer shield parts catalog 7-42 removal 4-126 output bin sensor tests 3-15

M
main drive assembly parts catalog 7-32 removal 4-113 service check 2-153 main fan removal 4-111 maintenance ESD-sensitive parts 4-1 flatbed white cushion 6-2 lubrication 6-1 maintenance kit 6-1 preventive 6-1 safety inspection guide 6-1 scanner glass 6-2 maintenance approach 1-1 maintenance kits 6-1 media specifications 1-9 Menu button, service check 2-154 menus 2-9 accessing service menus 3-1 accessing user menus 2-5 configuration menu 3-24 diagnostics menu 3-2 list of user menus 2-9 messages check device connection messages 2-56 service error codes 2-13 user attendance messages 2-42 user line 2 link messages 2-56 user status displays 2-38 Min Copy Memory 3-29 Model Name 3-18 models 1-1, 1-2, 7-1 450S cabling diagramparts catalog 7-46 operator panel 2-2 500S cabling diagramparts catalog 7-48 operator panel 2-2

P
packaging 7-71 page count Fuser Page Count 3-20 Page Count 3-18 permanent page count 3-18 Panel Menus 3-27 Panel Test 3-8 paper bin full sensor flag 4-124 paper deflector assembly inner 4-101 upper 4-138 paper feed jams 200 and 201remove cartridge 3-46 202open rear door 3-47 23x and 24x jams 3-43 23xduplex rear door 3-48 250MPF 3-40 260envelope feeder 3-41 290, 291, 292, and 294 scanner jams 3-49 access door and trays 3-39 access doors and trays 3-39

I-4 Service Manual

clearing 3-40 identifying jams 3-38 paper path 3-39 paper jam error codes 2-57 paper path 3-39 Paper Prompts 3-31 paper size sensing board 2-158, 4-125 paper specifications 1-9 parallel wrap tests 3-10 part number index 2-9 parts catalog 250-sheet paper drawer, option 7-59 250-sheet paper tray, option 7-60 500-sheet paper drawer, option 7-61 500-sheet paper tray, option 7-62 cabling 7-43, 7-44, 7-45 , 7-46 , 7-48, 7-50, 7-52, 7-56, 7-57 coversADF scanner 7-8 coversprinter 7-2 coversprintermodel 450S 7-2 coversprintermodel 500S 7-6 drivesmain drive and developer drive 7-32 duplex option 7-63 electronics card assemblies 7-40 power supplies 7-38 shields 7-42 envelope feeder 7-64 frame 1 7-10 frame 2 7-12 frame 3 7-14 high-capacity feeder 7-66, 7-68, 7-69, 7-70 hot roll fuser 7-34 integrated paper tray500-sheet 7-30 optional 250-sheet paper drawer 7-59 optional 250-sheet paper tray 7-60 options 7-71 paper feed alignment 7-28 autocompensator 7-25 multipurpose feeder 7-26 printhead 7-24 scanner ADFlower exit guide assembly 7-18 scanner ADFmotors and belts 7-19 scanner ADFpaper feed 7-17 scanner ADFpickup 7-16 scanner ADFsensors 7-20 scannerflatbed 7-22 transfer charging 7-36 pass thru plate 4-74 pick rolls, integrated tray autocompensator 4-105 pick tire integrated tray autocompensator pick roll 4-105 MPF 4-118 power takeoff shaft and spring 4-126 PPDS Emulation 3-27 preventive maintenance 6-1 print quality pages 3-7, 3-26 print registration 3-5

printhead adjustment 4-2 parts catalog 7-24 removal 4-127 service check 2-165

Q
quality printer all black page 2-160 background 2-162 banding 2-163 black bands on outer edges 2-163 blank page 2-161 blurred or fuzzy print 2-161 light print 2-164 random marks 2-161 residual image 2-163 toner on backside of printed page 2-164 scanner all black or blank 2-168 line compression 2-169 vertical streaks or lines 2-165 wavy lines 2-169 quality pages 3-7, 3-26 Quick Disk Test 3-16 Quick Test 3-6 , 3-11

R
redrive assembly parts catalog 7-12 removal 4-128 redrive door 4-58 REGISTRATION 3-5 registration 3-5 automatic scanner 3-30 Scanner Automatic Registration 4-4 Scanner Manual Registration 4-5 relocation kit 7-71 removal procedures and cautions 4-6 removals printer removals bevel gear 4-75 developer drive assembly 4-77 developer drive coupler kit 4-78 ESD cover 4-78 fuser assembly 4-79 fuser cover removal 4-95 fuser exit sensor 4-82 fuser exit sensor flag and spring 4-83 fuser lamp 4-86 fuser narrow media flag and spring 4-90 fuser narrow media sensor 4-88 fuser to LVPS AC cable 4-92 fuser transfer plate 4-97 fuser wiper cover assembly 4-54 gear release link 4-98 high voltage power supply 4-99

Index

I-5

inner paper deflector assembly 4-101 inner shieldmodel 450S 4-130 inner shieldmodel 500S 4-131 input sensor 4-102 integrated tray autocompensator assembly 4-103 integrated tray autocompensator pick roll assembly

4-105
interface card assembly 4-107 LCD inverter card assembly 4-108 LCD touchscreenmodel 450S 4-69 LCD touchscreenmodel 500S 4-67 left and right frame extensions 4-73 left cover handle holder 4-72 low voltage power supply (LVPS) 4-109 lower front cover assembly 4-71 lower paper deflector 4-117 main drive assembly 4-113 main fan 4-111 MPF arm assembly 4-116 MPF pick tire removal 4-118 MPF solenoid assembly 4-119 MPF lower front cover assembly 4-71 operator panel left cover assembly 4-61 operator panel right cover assembly 4-64 paper alignment assembly 4-122 paper bin full sensor flag 4-124 paper size sensing board 4-125 pass thru plate 4-74 power takeoff shaft and spring 4-126 printer left side cover 4-56 printer outer shield 4-126 printhead 4-127 redrive assembly 4-128 redrive door 4-58 right cover handle holder 4-72 right cover removal 4-58 signature button contact assembly 4-129 system board and inner shieldmodel 450S

CCD belt tension spring 4-19 CCD beth removal 4-17 cover closed actuator 4-22 cover closing actuator 4-21 document tray assembly 4-23 flatbed CCD module assembly 4-28 flatbed CCD ribbon cable 4-24 flatbed contact glass 4-31 flatbed interconnect card removal 4-33 flatbed paper length sensor assembly 4-35 flatbed scan assembly 4-38 flatbed scan motor assembly 4-41 flatbed white cushion 4-32 front flatbed cover 4-11 hard disk 4-44 home sensor 4-46 lower exit guide assembly 4-47 pickup solenoid assembly 4-48 scan cover (flatbed) removal 4-11 scanner control card 4-48 scanner flatbed glass holder assembly 4-50 scanner left side cover 4-10 scanner right side cover 4-12 separator assembly torque limiter 4-52 upper glass holder 4-53 Require Standby 3-34 right cover handle holder removal 4-72 right cover removal 4-58

S
safety information xvii safety inspection guide 6-1 scanner parts catalog 7-8, 7-16, 7-17, 7-18, 7-19 , 7-20 , 7-22 specifications 1-4 Scanner Automatic Registration 4-4 scanner control card connectors 5-17 removal 4-48 Scanner Manual Registration 3-23 scheduled maintenance 6-1 sensors flatbed paper length sensor assembly 4-35 fuser exit sensor 4-82 fuser narrow media sensor 4-88 home sensor 4-46 input 4-102 locations 5-1, 5-2 output bin sensor, integrated paper tray 2-156 paper bin full 4-124 paper size sensing board 4-125 parts catalog (scanner) 7-20 toner 4-132 serial number 3-18 serial wrap tests 3-10

4-130
system board and inner shieldmodels 500S

4-131
toner sensor 4-132 touchscreen bezel 4-66 transfer roll assembly 4-132 upper front cover hinge assembly 4-136 upper paper deflector assembly 4-138 upper sub cover 4-55 upper tray cover 4-133 upper tray cover (paper support) 4-56 USB card 4-139 scanner ADF and flatbed ADF attach screws 4-13 ADF CCD module assembly 4-14 ADF complete assembly 4-15 ADF front cover 4-6 ADF pick assembly 4-7 ADF rear cover 4-7 ADF top cover 4-9 ADF upper entrance guide assembly 4-16

I-6 Service Manual

service checks 202.03 error code 2-95 202.06 error code 2-95 290.00 error code 2-96 290.01 error check 2-98 290.02 error code 2-100 290.10 error code 2-102 291.00 error code 2-104 291.01 error code 2-105 291.02 error code 2-106 292.00 error code 2-107 293 error code 2-108 294.00 error code 2-109 294.01 error code 2-110 294.02 error code 2-112 294.03 error code 2-113 298.01 error code 2-115 298.02 error code 2-115 842.xx error code 2-115 843.xx error code 2-116 845.00 error code 2-117 848.00 error code 2-118 848.01 error code 2-118 900.90 error code 2-118 900.xx error code 2-118 927.xx error codefan 2-119 950.00 through 950.29 EPROM mismatch failure 2-120 ADF paper length 2-122 cartridge fan 2-119 charge roll 2-123 cold fuser 2-134 cover closed sensorsflatbed 2-124 cover open switch/cableprinter 2-125 dead machine 2-125 DRAM memory options 2-155 duplex option 2-127 envelope feeder 2-129 flash memory option 2-155 flatbed size sensor 2-131 fuser 2-132 fuser exit sensor 2-138 fuser narrow media sensor 2-139 fuser solenoid 2-140 hard disk option 2-155 high-capacity feeder input tray 2-141 hot fuser 2-135 , 2-136, 2-137 input sensor 2-146 input tray, optional 2-147 interface card 2-148 LCD touchscreen contrast controlmodel 450S

2-149
LCD touchscreen displaymodel 500S

2-149
main drive 2-153 main fan 2-119 network card (976.xx) 2-155 network card (977.xx) 2-155 operator panel Help and Home buttonsmodel 450S

operator panel Menu button450S 2-154 operator panel right cover assembly 2-154 options 2-155 output bin sensor 2-156 paper feed 2-156 paper size sensing board 2-158 paper width sensormodel 500S 2-123 parallel port 2-159 print quality 2-160 printhead 2-165 scan quality 2-165 signature button assembly 2-170 system board 2-170 toner sensor 2-171 transfer roll 2-172 service error codes 2-13 shield inner shieldmodel 450S 4-130 inner shieldmodel 500S 4-131 outer 4-126 signature button contact assembly removal 4-129 specifications acoustics 1-8 data streams 1-4 dimensions 1-6 electrical 1-7 environment 1-8 media guidelines 1-9 memory configuration 1-5 operating clearances 1-5 power requirements 1-7 resolution 1-4 scanner 1-4 start 2-1 strobe adjustment 3-19 sub error codes 2-13 switch, cover closed 2-125 symptoms duplex option 2-12 envelope feeder 2-12 high-capacity feeder 2-11 paper trays 2-12 printer (MFP) 2-10 scannerADF symptoms 2-11 scannerflatbed 2-11 scannerscan quality 2-11 system board barcode 7-41 connectors 5-3 parts catalog 7-40 removalmodel 450S 4-130 removalmodel 500S 4-131 service check 2-170

2-154

Index

I-7

T
theory of operation autocompensator 3-36 autoconnect cabling and connectors 3-37 duplex unit 3-37 option microcode 3-37 toner sensor removal 4-132 tools 1-17 Top Margin duplex 3-11 simplex (front side) 3-5 touchscreen 2-2 , 2-3 bezel removal 4-66 removal 4-67 service checkmodel 450S 2-149 service checkmodel 500S 2-149 transfer roll assembly parts catalog 7-36 removal 4-132 service check 2-172

U
UICC #1 model X642e operator panel card 2-149 , 2-154, 5-12 model X644e/X646e operator panel card 5-14 UICC #2 LCD inverter board 5-16 unique tools 1-17 upper front cover hinge assembly removal 4-136 upper paper deflector 4-138 upper sub cover, removal 4-55 upper tray cover removal 4-133 USB card connectors 5-10 location 2-4 removal 4-139 user attendance messages 2-42 user line 2 link messages 2-56 user status displays 2-38

W
warm up time 3-20 Wipe Disk 3-33 wiper cover 4-54 Wiper Message 3-35 wrap tests 3-10

I-8 Service Manual

Part number index

P/N 1319128 40X0001 40X0009 40X0021 40X0024 40X0025 40X0026 40X0027 40X0028 40X0030 40X0032 40X0033 40X0034 40X0036 40X0039 40X0040 40X0042 40X0043 40X0044 40X0045 40X0046 40X0048 40X0049 40X0050 40X0051 40X0052 40X0054 40X0058 40X0059 40X0060 40X0061 40X0062 40X0065 40X0066 40X0069 40X0070 40X0070 40X0072 40X0074 40X0076 40X0077 40X0079 40X0084 40X0085 40X0086 40X0098 40X0099 40X0100 40X0101 40X0103 40X0105

Description

Page

Parallel wrap plug - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-159, 3-10 Fuser wiper cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7 TLI/ID/serial number labelblank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5, 7-7 Cartridge holddown spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Right frame extension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 Left frame extension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 Contact, RSF ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 Upper redrive deflector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Upper diverter spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Redrive assembly, 500 in/500 out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Transfer deflector with brush - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Machine mounting pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Signature button contact assembly with cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-15, 7-45 Toner sensor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Developer support roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Upper paper feed deflector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Inner paper feed deflector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Input sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Gear guard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 ESD shield with label - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Paper size sensing board assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-13, 7-44 Paper switch activate spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Gear release link - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Counterbalance spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5, 7-7 Standard bin level sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Standard bin level sensor bracket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Main fan with cable, 500-sheet output - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-13, 7-51 Output paper level flag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Extension guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 External ground clip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 Laser printhead cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-24, 7-44 Printhead assembly (includes all cables) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24 Frame extension, nut plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 Pick arm assembly500-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25 Parts packet, bellcrank assembly for500-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25 Pick roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59, 7-61, 7-70 Pick tires, pick roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25 Paper out flag500-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25 Paper size/autocompensator cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-25, 7-44 Pick roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27 Multipurpose feeder paper out flag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27 Multipurpose feeder lower deflector assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27 Paper feed alignment assembly paper feed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29 Reference ground clip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29 Parts packet (reference adjust) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29 Tray assembly500-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31 Side restraint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31 115 V Maintenance kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 220 V Maintenance kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Pass thru plate500-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31 Restraint pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31

Part number index

I-9

40X0106 40X0107 40X0111 40X0112 40X0113 40X0114 40X0115 40X0120 40X0121 40X0122 40X0123 40X0124 40X0125 40X0126 40X0127 40X0129 40X0130 40X0131 40X0132 40X0133 40X0134 40X0135 40X0149 40X0150 40X0151 40X0152 40X0153 40X0156 40X0159 40X0160 40X0161 40X0162 40X0163 40X0165 40X0174 40X0179 40X0182 40X0183 40X0197 40X0207 40X0208 40X0209 40X0213 40X0215 40X0223 40X0224 40X0225 40X0226 40X0227 40X0229 40X0230 40X0231 40X0232 40X0236 40X0238 40X0239 40X0249 40X0254 40X0255

Back restraint - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31 Gearbox with motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33 Power takeoff shaft500-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33 Power takeoff shaft spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33 Bevel gear with grease packet and washer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33 Developer drive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33 Parts packet, developer drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33 Fuser wiper cavity cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Fuser cover assembly kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Fuser lamp, 115V - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Fuser lamp, 220V - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Narrow media sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Exit sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Parts kit, charge roll link asm, left side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 Charge roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 Parts kit, right side charge roll link assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 Transfer roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 Transfer roll assembly right arm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 Transfer roll right spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 Transfer pivot shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 Transfer roll left spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 Transfer roll left arm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37 Inner shield assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-42 Outer shield - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-42 USB board assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7 Ethernet shield (blank) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-42 INA flat cover (blank) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-42 Bottom/front autoconnect cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45 Main drive motor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-51 MPF sensor cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43 Ground cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-51 System board to fuser board cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47, 7-49 Fuser AC lamp to LVPS cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47, 7-49 Parts packet - - - - - - - - - - - - - - - 7-11, 7-13, 7-15, 7-24, 7-25, 7-27, 7-29, 7-33, 7-35, 7-37, 7-39, 7-42 Parts packet (cable ties) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5, 7-7 Nyogel 744 grease packet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Wear strip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31 Plate, 500-sheet tray wear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31 100 V Maintenance kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 EP duct - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Blower duct - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Gear #60 MPF shield - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Tray bias assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Paper low/out sensor card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25 HVPS/input sensor/toner sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - 7-15, 7-39, 7-43, 7-45 LVPS to system board cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45 Right side hand holder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 Fuser AC to fuser lamp cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35, 7-47, 7-49 Parts packet (fuser mounting screw) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Narrow media sensor cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Exit sensor cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Left side hand holder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 Redrive door assembly 500 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Exit/narrow media sensor cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Narrow media flag/spring kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Exit sensor flag/spring kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 EP DC fan assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15, 7-51 Parts packet, redrive mounting screws - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13 Power cord set (8 ft right angle)Argentina - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39

I-10 Service Manual

40X0256 40X0257 40X0258 40X0259 40X0260 40X0264 40X0271 40X0272 40X0280 40X0281 40X0285 40X0290 40X0291 40X0293 40X0294 40X0295 40X0301 40X0303 40X0304 40X0305 40X0306 40X0310 40X0450 40X0451 40X0452 40X0453 40X0456 40X0457 40X0458 40X0460 40X0461 40X0462 40X0463 40X0464 40X0465 40X0466 40X0467 40X0468 40X0469 40X0470 40X0471 40X0472 40X0473 40X0474 40X0475 40X0476 40X0478 40X0479 40X0480 40X0481 40X0482 40X0483 40X0484 40X0485 40X0486 40X0487 40X0489 40X0490 40X0491

Power cord set (8 ft right angle)Bolivia and Peru - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord set (8 ft right angle)Chile, Uruguay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord set (8 ft right angle) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord set (6 ft right angle)Brazil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord set (8 ft right angle, 13 amp)United States - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Standard bin level sensor cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-13, 7-43 Power cord setHong Kong - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord set (8 ft right angle)Japan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord set (6 ft straight)Korea - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord setTaiwan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Frame clip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 RS232C serial interface card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Parallel 1284-B interface card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Power cord set (8 ft right angle)UK - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord setDenmark, Norway, and Sweden - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord setIsrael - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord setAS/NZ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord setPRC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Power cord setBotswana, Lesotho, Namibia, Pakistan, and South Africa - - - - - - - - - - - - - - - - - - - - 7-39 Power cord setSwitzerland - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 High voltage contact kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 Multipurpose feeder pick arm assembly with solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-27, 7-51 Complete ADF 500S assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 Document tray 500S assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 ADF top cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 Pickup assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-16 Pickup arm assembly solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-21, 7-56 Complete flatbed scanner 500S assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 ADF CCD module assembly500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-18 Lower exit guide assembly500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-18 Feed motor (ADF feed) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19 ADF scan motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19 ADF scan cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 ADF front cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 ADF rear cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 Flatbed white cushion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Upper cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7 Upper tray cover (paper support) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7 Upper sub cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7 Left cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5, 7-7 Right cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7 Left side cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5, 7-7 Right side cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7 Front cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Scan cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Cover bezel 500S. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 Flatbed CCD module assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Flatbed CCD drive belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Flatbed scan motor, including flatbed scan motor to flatbed interconnect card cable - - - - - 7-23, 7-53, 7-55 Parts packet, sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-9, 7-21, 7-23, 7-53, 7-55, 7-56, 7-57, 7-58 Belts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19 Flatbed contact glass - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Glass holder assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Flatbed interconnect card assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Motor driver card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-21, 7-56 Flatbed CCD ribbon cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23, 7-53, 7-55 Hard disk assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 Belt tension spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Flatbed paper size sensor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23, 7-53, 7-55

Part number index

I-11

40X0493 40X0494 40X0495 40X0496 40X0497 40X0498 40X0502 40X0506 40X0507 40X0509 40X0510 40X0511 40X0512 40X0513 40X0514 40X0515 40X0516 40X0519 40X0520 40X1376 40X1377 40X1378 40X1455 40X1508 40X1509 40X1510 40X1512 40X1513 40X1514 40X1515 40X1562 40X1564 40X2529 40X2590 40X2591 40X2592 40X2669 40X2722 40X2792 40X2793 40X3230 40X3231 40X3232 40X3233 40X3234 40X3235 40X3236 40X3237 40X3243 40X3246 40X3247 40X3248 40X3249 40X3252 40X3254 40X3255 40X3262 40X3296 40X3297

Multipurpose tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7 LCD touchscreen display assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 Operator panel left cover assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 Operator panel right cover assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 LCD touchscreen inverter card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 Scanner control card 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 ADF CCD to flatbed interconnect card 36-pin cable 500S - - - - - - - - - - - - - - - - - - - - - - - - - - 7-58 MDC to flatbed interconnect card 36-pin cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57, 7-58 Modem 30-pin cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-53, 7-55 Hard disk IDE 50-pin cable 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-55 Hard disk 4-pin power cable 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-55 Inverter 32-pin cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-49 32-pin cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-49 Flatbed cover closed actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Flatbed cover closing actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Upper front cover hinge assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7, 7-49 Counterbalance spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7 Modem card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 Interface card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 MarkNet 8020 Gigabit Ethernet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 MarkNet 8030 Fiber Ethernet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 MarkNet 8050 wireless, US - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 64MB Flash card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 128MB memory option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 256MB memory option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 512MB memory option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Japanese font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Simplified Chinese font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Traditional Chinese font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Korean font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 MarkNet 8050 wireless, non-US - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 32MB Flash card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 IPDS SCS/TNe card assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-71 Fuser assembly w/220 V lamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Fuser assembly w/100 V lamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Fuser assembly w/115 V lamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35 Power supply board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-68 System board assembly (network), (Board ID Q0016000) 500S - - - - - - - - - - - - - - - - - - - - - 7-41 Bar code card assembly500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 PRESCRIBE card assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 250-sheet paper drawer, complete assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59 Tray assembly, option250-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60 Pick arm assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59 Option pass thru sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59, 7-61, 7-70 Bin low sensor with cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59, 7-61 Side restraint250-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60 Back restraint250-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60 Base assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59 Drawer assembly, complete500-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 Pick arm assembly500 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 Base assembly, 500-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 Complete envelope option - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-65 Complete option assembly (A4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67 2000-sheet option control card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67 Front door assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67 Pick arm assembly2000-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-70 AC external jumper cord - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-68 Complete ADF assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9 Document tray assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9

I-12 Service Manual

40X3298 40X3299 40X3301 40X3302 40X3303 40X3304 40X3305 40X3309 40X3310 40X3311 40X3312 40X3477 40X3478 40X3479 40X4178 40X4179 40X4180 40X4181 40X4243 40X4244 40X4275 40X4656 40X4657 40X4658 56P1228 56P1228 56P1279 56P2540 56P4102 56P4116 56P4129 56P4137 56P4145 56P4147 56P4150 56P4157 56P4195 56P4196 56P4230 7375947 99A0063 99A0120 99A0121 99A0263 99A0272 99A0275 99A0292 99A0447 99A0654 99A0658 99A0676 99A0677 99A0681 99A1818 99A1929

Complete flatbed scanner assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Cover bezel 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 LCD mono touchscreen display assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 Operator panel left cover assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 Operator panel right cover assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 LCD (mono) touchscreen inverter card 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5 Scanner control card 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 Upper front cover hinge assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-3, 7-47 System board assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41 Lower exit guide assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-18 Flatbed interconnect card assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23 Bar code card assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-41, 7-71 Forms card assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-41, 7-71 PrintCryption card assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-41, 7-71 PrintCryption card assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-41, 7-71 Forms card assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-41, 7-71 PRESCRIBE card assembly 450S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Bar code card assembly 500S - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 LVPS/AIO115 V ac - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 LVPS/AIO220 V ac - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 High voltage power supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 Upper entrance guide kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17 Entrance guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17 Sub ADF separator guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17 Bellcrank spring arm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 Bellcrank250-sheet paper tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59 Wear strips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60 Bellcrank spring500-sheet option tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 Duplex assembly500-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-63 Universal adjustable tray assembly400-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Paper out arm250-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59 Side restraint500-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62 Paper out arm500-sheet drawer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 Back restraint500-sheet tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62 Complete tray assembly500-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62 Door hinge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67 Plate500 sheet wear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62 Pass thru plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62 Clip250 sheet pass thru - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60 Relocation kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71 Switch activate spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-59, 7-61 Restraint pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-60, 7-62 Plate250-sheet tray wear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60 Parts packet, screws - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59, 7-61, 7-70 Drive shaft250-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-59, 7-69 Power takeoff spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59, 7-61, 7-69 Wear strips - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62 Drive shaft500-sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61 Paper low switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-68 Door magnet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67 Parts packet, nuts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-67, 7-68 Parts packet, washers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67 Wear strip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67 Wear dimple strip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67 Bellcrank spring250-sheet paper tray - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59

Part number index

I-13

I-14 Service Manual

e-STUDIO 500S

eWiring diagram AIOprinter

e-STUDIO 450S Wiring diagram AIOscanner

e-STUDIO 500S Wiring diagram AIOscanner