Multifunction - Color X500, X502

Edition January 25, 2008
Lexmark X500n-X502n MFP
7100-XXX
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark international, inc., registered in
the United States and/or other countries.
7100-xxx
Edition: January 25, 2008
The following paragraph does not apply to any country where such provisions are inconsistent with local law:
LEXMARK INTERNATIONAL, inC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or
implied warranties in certain transactions; therefore, this statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the
information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the
programs described may be made at any time.
Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road,
Lexington, Kentucky 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any
of the information you supply in any way it believes appropriate without incurring any obligation to you.
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these
available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or
imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that
does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in
conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the
user’s responsibility.
Lexmark, Lexmark with diamond design is a trademark of Lexmark international, inc., registered in the United States and/
or other countries.
All other trademarks are the property of their respective owners.
© 2007 Lexmark International, 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 12G9738
7100-XXX
Table of contents
Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MFP Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General device technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Print engine specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Scan specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Copy specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fax specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Standard inspection and cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Understanding the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
User status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
MFP symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Print quality symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Printer service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
CPU fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Developer drive assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Transfer belt unit service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Transfer roller clutch service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Transfer belt cleaning roller clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Paper feed clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Registration clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
OPC belt marker sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Erase lamp service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Power supply fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Fuser fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
High voltage power supply (HVPS) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Low voltage power supply (LVPS) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Fuser thermistor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Fuser assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Laser unit assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
HVPS connection service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Toner empty sensor (sender-TPD) service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Toner empty sensor (receiver-TTR) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Lower feed unit (secondary paper assembly) service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Tray empty service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Paper tray missing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Toner low/empty service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Table of contents
iii
7100-XXX
Waste toner bottle service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Missing toner cartridge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Missing photodeveloper cartridge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
Transfer roller missing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Cover open service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
OPC belt (photodeveloper) cartridge drive service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36
Missing fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36
Paper size sensing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37
Printer no power service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
Toner feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
Waste toner feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
USB service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
Network service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
Black page copy service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41
Flatbed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41
ADF streak service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41
ADF paper feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Modem / fax card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
Printer paper feed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
Background service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
Back stain service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46
Banding service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47
Black line service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Color misregistration service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
insufficient fusing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
insufficient gloss service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
Jitter service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Missing image at edge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
Mixed color image service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54
Mottle service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
Residual image service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56
Ribbing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57
Smear service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58
Toner drop service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59
Vertical line service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Vertical staggering image service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61
Vertical white band service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62
White band service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63
White line I service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64
White line II service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64
White spot / black spot service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65
White print service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66
Wrinkle / image migration service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67
Uneven density (right and left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
Spacing table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69
Roller specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69
Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Understanding the MFP operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Retrieving, printing and restoring the MFP settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Printing the maintenance and configuration pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Setting the country code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
iv Service Manual
7100-XXX
Scanner calibration and registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Display info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Print Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Scan Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Fax Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Density Tune Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Printer theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Electrophotographic Process (EP process). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
EP Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Summary of the EP process on the X500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
X500 EP steps in detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Paper path components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
X500n specific information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Paper jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Accessing jam areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Paper Jam A1, rear (tray 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Paper Jam A2, rear (tray 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Paper Jam B rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Paper Jam C rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
ADF paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removal and cleaning precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Photodeveloper cartridge 4-3
During transportation/storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
MFP removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cleaning roller cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Transfer belt cleaning roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Transfer belt unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Transfer roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fuser assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Waste toner bottle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Photodeveloper cartridge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Secondary paper feed assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Front cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Rear cover assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Left front cover removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Left rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Upper right rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Upper left rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Laser unit assembly (printhead) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Erase lamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Right side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Front door interlock switch with bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Waste toner bottle holder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Developer drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Toner sensor (sender) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
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Cleaning roller clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
Main motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Main drive gear assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Waste toner feeder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Rear removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
Bracket assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
Paper guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
Paper guide C assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
Paper feed roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
Paper exit assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
Registration assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
Left side removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34
Engine controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34
System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36
System board cage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39
High voltage power supply (HVPS) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40
Low voltage power supply (LVPS) with cage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41
HVPS cage removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42
Toner present sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42
Toner sensor (receiver) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
Left tray guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
Modem speaker removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44
Fuser fan assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44
Modem card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46
Top removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
Marker sensor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47
Waste toner auger removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Waste toner agitator removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Power supply fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49
Scanner assembly removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50
Flatbed assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50
Scanner arm removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53
ADF unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54
ADF mechanism cover removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-56
Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-58
Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Printer front and rear views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Scanner locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Electronic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Printer engine sensor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
MFP circuit board locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Fan/motor and interlock switch locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Clutch locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Symbol and part name table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Engine controller board wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
RIP board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
RIP card voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Engine controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Low voltage power supply (LVPS) board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
High voltage power supply (HVPS) board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Modem Card voltages and signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
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Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
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Notices and safety information
The following laser notice labels may be affixed to this printer.
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1)
laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC
60825-1.
Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser
that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers.
The laser system and printer are designed so there is never any human access to laser radiation above a Class
I level during normal operation, user maintenance, or prescribed service condition.
Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). in anderen
Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (international
Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.
Laserprodukte der Klasse I gelten als unschädlich. Im inneren des Druckers befindet sich ein Laser der Klasse
IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795
Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der
Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung,
die Klasse I übersteigen würde, Menschen keinesfalls erreicht.
Avis relatif à l’utilisation de laser
Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant
les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1
relatives aux produits laser de Classe I.
Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est
équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant
sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont
conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision,
l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .
Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo
J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai
requisiti della norma CEI 60825-1.
I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe
IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795
nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la
stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non
ricevano radiazioni laser superiori al livello della classe 1.
Notices and safety information
ix
7100-XXX
Avisos sobre el láser
Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1)
establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en
los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de
Clase I (1).
Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de
Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a
795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse
afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el
mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.
Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR
Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da
Classe I, em conformidade com os requisitos da norma IEC 60825-1.
Os produtos laser da Classe I não são considerados perigosos. internamente, a impressora contém um produto
laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de
comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma
a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I
durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.
Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten
zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.
Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van
klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795
nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie
conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals
voorgeschreven is voor klasse 1.
Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der
nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse
I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.
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Laserilmoitus
Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.
Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan
5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat
rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön,
ylläpidon tai huollon aikana.
Huomautus laserlaitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen
ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.
Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5
milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on
suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin
toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.
VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso
säteeseen.
VARNinG! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad.
Betrakta ej strålen.
Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av
Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.
Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av
en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer.
Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för
laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan
föreskriven serviceåtgärd.
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er
i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som
består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.
Notices and safety information
xi
7100-XXX
Avís sobre el Làser
Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat
J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe
I que compleix els requisits d’IEC 60825-1.
Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb
(3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795
nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la
radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment
d’usuari ni durant els serveis que satisfacin les condicions prescrites.
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Notices and safety information
xiii
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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 sécurité
• La sécurité de ce produit repose sur des tests et des
•
•
•
agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume
aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.
Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de
maintenance qualifié.
Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel
d'entretien qualifié devra prendre toutes les précautions nécessaires.
ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du
produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve
de vigilance si l'exécution de la tâche exige que le produit reste sous tension.
Norme di sicurezza
• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti
•
•
•
specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle
parti.
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di
assistenza autorizzato.
Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza
autorizzato deve, quindi, adottare le precauzioni necessarie.
ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto.
Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per
eseguire l'intervento.
Safety information
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7100-XXX
Sicherheitshinweise
• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und
•
•
•
bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine
Verantwortung oder Haftung für die Sicherheit übernommen.
Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines
elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende
Vorsichtsmaßnahmen treffen.
ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem
Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des
Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten
an den Strom angeschlossen sein muß.
Pautas de Seguridad
• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes
•
•
•
específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no
autorizadas.
La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal
cualificado de mantenimiento.
Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de
la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones
necesarias.
PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está
trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para
trabajar con él, debe conectarlo.
Informações de Segurança
• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes
•
•
•
específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição
não autorizadas.
As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não
devem ser utilizadas por outras pessoas.
Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.
Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.
CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão
perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da
tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para
realizar a tarefa necessária.
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7100-XXX
Informació de Seguretat
• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components
•
•
•
específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.
La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està
destinada
a ningú que no ho sigui.
El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei
d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre
les mesures convenients.
PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu
treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per
treballar amb l'equip, l'heu de connectar.
Safety information
-xvii
7100-XXX
Lithium information
CAUTION: There is a lithium battery on your system board. RISK OF EXPLOSION IF
REPLACED BY INCORRECT TYPE. The battery is non-replaceable. Do not replace,
recharge, disassemble, or incinerate a lithium battery. Discard used batteries according to the
manufacturer’s instructions and local regulations.
Lithium-Information
ACHTUNG: Auf Ihrer Systemplatine befindet sich eine Lithiumbatterie. Beim Einsetzen eines
nicht passenden Batterietyps besteht ein Explosionsrisiko. Die Batterie darf nicht
ausgetauscht werden. Lithiumbatterien dürfen auf keinen Fall ausgetauscht, wieder
aufgeladen, auseinander genommen oder verbrannt werden. Befolgen Sie zum Entsorgen
verbrauchter Batterien die Anweisungen des Herstellers und die örtlichen Bestimmungen.
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7100-XXX
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.
Appendix B contains representative print samples.
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.
Preface
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7100-XXX
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7100-XXX
1. General information
The Lexmark™ X500n and X502n are color laser MFPs that combine print, scan, copy, and fax functions.
The X500n and X502n are the ideal MFPs for presentations, business graphics, line art, and text. They use
laser diode electrophotographic technology to deliver remarkable quality print images and text. The scan
and copy functions work with A4 , letter, and legal (ADF only) size paper. Photographic quality images are
possible with scan function. The FAX function delivers a wide range of functionality to the office user. The
MFPs can be used as shared network or desktop devices.
Models
The Lexmark X5xx MFPs are available in the following models:
Model
Configuration
Machine type
X500n
Print, copy, scan, network
7100-010
X502n
Print, copy, scan, fax, network
7100-110
General information
1-1
7100-XXX
MFP Specifications
General device technical specifications
Interfaces
X500n
X502n
USB 2.0
X
X
Ethernet 10/100 Base T
X
X
Note: The USB 2.0 and network interfaces can be used simultaneously.
The USB interface supports:
•
•
•
•
•
•
•
•
Windows 98 SE
Windows Me
Windows NT
Windows 2000 Professional
Windows XP Operating Systems
Windows Server 2003 Operating Systems
Windows Vista 32/64 bit
Macintosh OS X version10.1—10.4 (Power PC and Intel)
Note: For USB attachment, a USB cable (P/N 12A2405) is recommended and must be ordered separately.
The standard Ethernet connection and optional N2100 Series print servers support the following protocols:
• TCP/IP–The TCP/IP standard set of application services are supported including DHCP, BOOTP,
•
WINS, SNMP (MIB-2, host resources MIB, printer MIB, enterprise MIB, SNMP traps), HTTP, LPR/LPD,
FTP, IPP1,SLP, DDNS
AppleTalk
This MFP with standard Ethernet supports an Embedded Web Server. The current status of the operator
panel is viewable using the resident Web pages.
Processor
ARM-11core running at 366mhz.
Supported operating systems
This MFP is compatible with applications running under the following operating systems for either local or
network connections:
Macintosh
• Macintosh OS X version 10.2—10.4 and above. (Power PC and Intel)
The software applications that operate with most Apple LaserWriter printers will generally operate with this
printer.
Download the latest Lexmark printer PPD files or printer drivers from www.lexmark.com.
1-2 Service Manual
7100-XXX
Microsoft Windows
•
•
•
•
•
•
•
•
Microsoft Windows Me
Microsoft Windows 2000 Professional
Microsoft Windows 2000 Server
Microsoft Windows 2000 Advanced Server
Microsoft Windows XP Home
Microsoft Windows XP Professional
Microsoft Windows Server 2003
Microsoft Windows Vista 32/64 bit
Download the latest printer drivers from http://www.lexmark.com.
The Windows software applications, which operate in the operating systems listed above, are best suited to
run with the drivers supplied with this MFP. The drivers for Windows take advantage of the MFP’s functions
and increase the MFP’s performance wherever possible.
Memory configuration
Standard DRAM
128MB
Optional SDRAM
N/A
Max DRAM
128MB
Physical specifications and weight (WIP)
The following table contains the dimensions and weights for each MFP model and option. This does not
include packaging but does include the print cartridge that ships with the MFP.
Width
Depth
Height
Weight2
inch
inch
inch
lb
mm
mm
mm
kg
18.9
17.2
21
77.0
480
437
531
35.0
18.1
18.5
7.3
13.3
460
470
185
6.0
MFP
Lexmark X500n/
X502n1
Paper options
530-Sheet drawer
530-Sheet tray
11.2
14.4
4.5
4.2
285
365
115
1.9
Standard tray
10.8
13.0
2.2
2.2
275
330
55
1.0
Tray set to legal
10.8
15.9
2.2
2.4
275
405
55
1.1
1
Comes with standard input tray and starter cartridges.
2
Weight does not include packaging or pubs.
General information
1-3
7100-XXX
Operating clearances
MFP sides
X5xxn
X5xxn with 530-sheet tray
Left side
8 in (203 mm)
8 in (203 mm)
Right side
20 in (508 mm)
20 in (508 mm)
Front
28 in (711 mm)
28 in (700 mm)
Rear
10 in (254 mm)
10 in (254 mm)
Top
16 in (400 mm)
16 in (400 mm)
Packaging and shipping dimensions
MFP*
X500n / X502n
Width
Depth
Height
Weight
in
in
in
lb
mm
mm
mm
kg
23.4
22.6
29.9
77
595
575
760
42.0
Options
530-Sheet drawer
21.9
22.4
10.9
18.7
556
570
277
8.5
* Includes start-up kit (supplies)
Power and electrical specifications
Printing states
X5xxn
Off
0W
Average power while operating
Continuous printing
670 W
Power consumption, standby
Power saver on
35 W
Power saver off
200 W
Maximum current while operating
115 Volts
11 A
230 Volts
6A
Average current while operating
115 Volts
6.0 A
230 Volts
3.0 A
1-4 Service Manual
7100-XXX
Environment
Environment
Specifications
Operating
Air temperature—product operating
10 to 32.5°C (50 to 90.5°F)
Air temperature—product power off
5 to 35°C (41 to 95°F)
Air relative humidity
15 to 80%
Altitude
0—2,500 m (0—8,200 ft.)
Ship / Storage
Temperature-printer and supplies
0 to 35°C (32 to 95°F)*
Relative humidity
10 to 90% RH
Atmospheric pressure
613 to 1607 hPa (460 to 800 mm Hg)
*Severe High 35 to 40°C (95 to 104°F), Severe Low -10 to 0°C (14 to 32°F). The period under severe shall not be deemed to be
continuous, but rather a total of such intermittent periods (48 hours at most for any one period).
General information
1-5
7100-XXX
Print engine specifications
Print engine resolution
600 x 600 dpi, 1200 x 600 dpi
Color balance settings
This MFP offers color balance control. It is a color correction option that allows you to increase or decrease
the amount of toner going to the page for all four color planes. The scale ranges from -10 to +10.
Emulations
Raster Graphics (CMYK bi-tone JBIG Compressed)
Print engine speed and performance
Pages/minute)
Media size
Standard tray
Mono
Color
Letter
Up to 31
Up to 8
A4
Up to 31
Up to 8
Legal
Up to 16
Up to 8
Transparencies
Up to 3
Up to 2
Thick card stock
Up to 3
Up to 2
Labels (letter &
A4)
Up to 5
Up to 3
Medium thick card
stock (letter & A4)
Up to 4
Up to 3
Envelopes
Up to 5
Up to 3
Print engine time to first print
Media type/Media size
First print time
Mono
Color
Plain paper mode / A4, letter
13 seconds
19 seconds
Transparency mode / A4, letter
23 seconds
29 seconds
Label—middle thickness stock / A4, letter
17 seconds
23 seconds
Middle thick stock—glossy / A4, letter
16 seconds
22 seconds
Thick stock / A4, letter
23 seconds
29 seconds
Envelope (1) mode / Commercial #10, International DL
18 seconds
24 seconds
Envelope (2) mode / Commercial #10, International DL
23 seconds
29 seconds
Note: Note: Time to first page (TTFP) is the time from the moment when the host sends the print signal
until the moment the trailing edge of the first page leaves the exit feed rollers. TTFP is measured using a
simple text (single character) page.
Note: Note: Warm up time, 60 seconds maximum, is the time elapsed from when the power is turned on
to when the Ready status is reached.
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7100-XXX
Print engine paper and media specifications
Print area
The printable area is up to 4.0 mm (0.158 in) from the top and bottom of the media, and up to 3.0 mm (0.118
in) from the left and right edges. Any information placed outside this specified printable area will not print.
For envelopes, the printable area is up to 4.0 mm (0.158 in) of the left and right edges, and 3.0 mm (0.118
in) of the top and bottom edges.
Print engine input and output configurations
The following table shows the standard number of input sources and output destinations, as well as the
estimated capacity of each. Capacity may vary and is subject to media specifications and MFP operating
environment. The capacities listed are based on plain paper at 75 g/m2.
Sources and capacities
X500n / X502n
Input sources
Number of standard sources
1
Number of optional input drawers
1
Maximum number of input sources1
2
Maximum input capacity
780
Input capacities
2
Standard input
Primary tray capacity
250
Total standard capacity
250
Optional input
Optional tray 1 capacity
250
Optional tray 2 capacity
530
Output destinations
Number of standard destinations
1
Output capacities
Standard output bin capacity (top)
Media up to 20 lb paper
1Optional
2The
250
input drawer is a 530-sheet capacity drawer. Only one optional drawer may be installed at any time.
MFP supports top output (facedown) as standard. No additional output options are available.
Note: All capacities are based on use of 20 lb paper.
General information
1-7
7100-XXX
Media input types and weights
Source
Type
Standard tray
Legal tray
530—Sheet tray
MFP menu Item
Paper
type
Paper1,2
(grain long)
Card stock
Xerographic or bond
paper
60—74
g/m2
(16-19 lb)
60—74
g/m2
(16-19 lb)
Plain paper
Light
Xerographic or bond
paper
75—120
g/m2 (20-32 lb)
75—120
g/m2 (20-32 lb)
Plain paper
Normal
100% Cotton
75—120
g/m2
(24-32 lb)
75—120
g/m2
(24-32 lb)
Plain paper
Heavy
Index
163 g/m2
(90 lb)
N/A
Card stock
Normal
Index
164—210 g/m2
(91-110 lb)
N/A
Card stock
Heavy
PN 12A5940
PN 12A5941
N/A
Transparency
N/A
Label
N/A
Envelope
Transparency3
Labels2
Envelopes
1
3
75—90
g/m2
(20—24lb)
Punched, embossed, water-marked, perforated, punched, inkjet paper or plastic-coated media should not be used.
2 Only
occasional use of paper labels in an office environment is supported.
Only PN 12A5940 and 12A5941 should be used.
There is no automatic paper type sensing. These settings should be manually set in the operator panel.
1-8 Service Manual
Paper
weight
Normal
7100-XXX
Media sizes
mm
Standard 250-sheet bin
Output
Set to legal
Optional 530-sheet tray 2
Universal 250 sheet tray
Input
Standard setting
Dimensions
Universal 250-sheet tray 1
Media sizes
in
A4
210 x 297
8.27 x 11.7
X
A5
148 x 210
5.83 x 8.27
X
JIS B53
182 x 257
7.17 x 10.1
X
X
Letter
216 x 279.4
8.5 x 11
X
X
Legal
216 x 356
8.5 x 14
Executive
184.2 x 266.7
7.25 x 10.5
X
Folio
216 x 330
8.5 x 13
X
X
Statement
139.7 x 215.9
5.5 x 8.5
X
X
Standard 250—sheet letter tray
104.8 x 210 to 215.9 x
297
4.125 x 8.27 to 8.5 x
11.7
Optional 250—sheet legal tray
104.8 x 210 to 215.9 x
355.6
4.125 x 8.27 to 8.5 x 14
Envelope sizes
Dimensions
Dimensions
98.4 x 225.4
3.875 x 8.9
COM 10 Envelope
104.8 x 241.3
4.12 x 9.5
X
X
X
DL Envelope
110 x 220
4.33 x 8.66
X
X
X
C5 Envelope2
162 x 229
6.38 x 9.01
X
X
X
Envelope2
176 x 250
6.93 x 9.84
X
X
X
Universal1
9
Envelope2
B5
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1 Select
Universal when using a non-standard size sheet of print material. The MFP formats the page for the maximum size 8.5 X 14
in(215.9 X 355.6 mm). Set the actual size from your software application.
2
Supported through the driver.
3
B5 may be supported in optional tray 1, but size sensing must be turned off.
Output capacity by media and source
Source
Media
Capacity
Orientation
Standard output bin (top)¹
Supports all sizes listed in the “Media
sizes” table
250 sheets (20 lb paper)
50 Transparencies
Collated
Facedown
General information
1-9
7100-XXX
Scan specifications
Resolution
1200 X 2400 dpi
Scan size
216mm X 297 mm (flatbed), Window size 220mm X 300mm
Scan depth
48 bits
Lamp warm up time
Less than 3 seconds
MTF
More than 30%
Depth of focus
-2 mm to +2 mm
Magnification
Less than 0.5%
Scanning
TWAIN
Connectivity
USB 2.0, and Ethernet (10/100 Base TX-TCP/IP only)
Push scan
Scan to E-mail, scan to FTP, scan to host PC
Web status monitor
Yes
Scanner driver (TWAIN) features
Scan mode
True color, grayscale, black & white
Contrast adjustment
Yes
Brightness adjustment
Yes
Color / Mono switch
Yes
Scan to E-mail feature
Network requirements
TCP/IP and an SMTP gateway
Authorization function
SMTP authentication, POP3 before SMTP
Register E-mail address
By Web page
Scan destination
Set up in scan profile
E-mail address maintenance
By Web page
Job Search
By profile name
Subject input
20 characters maximum. Entered by the Web page interface
Maximum E-mail data size
Supported file formats
1-10 Service Manual
TIFF, JPEG, PDF
7100-XXX
Copy specifications
Resolution
600 dpi X 600 dpi (flatbed), 600 X 300 dpi(ADF), Print from copy — 600 X 600 dpi
9600 dpi X 9600dpi w/ software interpolation
Original paper sizes
A4, Letter, Legal (ADF only), B5 (JIS), Executive
Copies per minute
Mono: up to 21, Color: up to 71
Time to first copy
Less than 30 seconds2
Multiple copies
99 copies maximum
Output paper sizes
A4, Letter, Legal (optional cassette only)
Image density adjustment
5 levels, manual only
Image quality modes
Text, Photo, and Mixed
Zoom
25% to 400% in increments of 1%
Present reduction ratio
US: 25%, 65%, 78%, 93%
Present enlargement ratio
US: 129%, 155%, 200%, 400%
EU: 25%, 71%, 86%, 93%
EU: 122%, 141%, 200%, 400%
Advanced copier features
Combine multiple copies into one copy.
2 into 1, 4 into 1. Can be toggled between landscape and portrait.
Electronic sort
Yes
Scan once print many
Yes
Limitless paper feed
Yes
Memory copy
Standard
Copy counter indicator
Standard
Jam recover auto restart
For print jams only.
Buzzer to finish job
Yes
ADF
ADF width
5.5 to 8.5 inches (139.7 to 215.9 mm)
ADF length
5.5 to 14 inches (139.7 to 355.6 mm)
ADF capacity
35 sheets
1 - assumes 50% coverage
2 - Does not include scanner and printer warm-up time.
Fax specifications
Phone network connectivity
Phone networks types supported
Both PSTN and PABX are supported.
Compatibility
T30(ITU-T Super G3) is supported.
Color fax is not supported.
Modem speed
Automatic fallback: 33600 bps
V34, V17, V29, and V27ter are supported for image
transmission. V8, and V21 are supported for control channels.
Compression
MH, MR, MMR, and JBIG
General information
1-11
7100-XXX
Document Sizes supported
ADF width
5.5 to 8.5 inches (139.7 to 215.9 mm)
ADF length
5.5 to 14 inches (139.7 to 355.6 mm)
ADF capacity
35 sheets
Flatbed width
8.5 inches (216 mm)
Flatbed length
11.7 inches (297 mm)
Scanning width
215.9 mm maximum
Printing width
Legal – 215.9 mm X 355.6 mm
Letter – 215.9 mm X 279.4 mm
A4 - 210.0 X 297.0 mm
Fax scan resolutions
Horizontal
Fixation
200 dpi
8 dot/mm
Vertical
Standard
100 dpi
3.85 dot/mm
Fine
200 dpi
7.7 dot/mm
Photo
200 dpi
7.7 dot/mm
Miscellaneous FAX specifications
Halftone/error diffusion
Error diffusion
Speed dial
50 entries (name 20 characters, number 40 digits)
Quick dial
20 entries (name 20 characters, number 40 digits)
On hook dial
Yes
Direct Fax number entry
Yes
Re dial
Yes
Transmission
Immediate transmission
Yes
Memory transmission
Yes
Page retransmission
Yes
Error correction mode
Yes
Broadcasting
Yes (100 entries)
Reception
FAX only mode
Yes
Manual mode
Yes
Auto reduction
Yes (Threshold 74%)
Error correction mode
Yes
Reports
Activity report
Yes
Transmission verification report
Yes
Power failure report
Yes
Phone book list
Yes
Quick dial list
Yes
Speed dial list
Yes
Memory manage list
Yes
User parameter list
Yes
Clear memory transmission file
Memory job clear
Standard
All clear
Standard
1-12 Service Manual
7100-XXX
Media guidelines
Paper designed for use with xerographic copiers should provide satisfactory print quality and feed reliability.
Other media types may be suitable. We recommend that users test any particular brand for suitability to
their applications. Refer to the MFP User's Guide for additional media specifications.
Paper
• Rough, highly textured, limp, or pre-curled papers will result in lower print quality and more frequent
paper feed failures.
• Colored papers must be able to withstand 338°F (170°C) fusing temperature.
• Preprinted forms and letterheads should be selected using guidelines in the MFP User's Reference.
The chemical process used in preprinting may render some papers unsuitable for use with the MFP.
• Unsuitable papers include punched, embossed, water-marked, perforated media, any kind of inkjet
paper or plastic-coated paper.
• Recycled paper less than 75 g/m2 (20 lb) may cause unacceptable results.
The laser printing process heats paper to high temperatures of 170°C (338°F). 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.
Envelopes
Should be fed with short edge first, flap down and to the right.
• If envelope wrinkling occurs, refer to the User's Reference for correct loading and stacking of
envelopes.
• All envelopes should be new, unused, and without damage.
• Envelopes with excessive curl or twist exceeding 6.0 mm, those stuck together, those with bent corners
or nicked edges, or those that interlock should not be used.
• Minimum weight: 90 g/m2 (24 lb).
• The following envelopes should not be used:
—
—
—
—
Envelopes with windows, holes, perforations, cutouts, or deep embossing
Envelopes with metal clasps, string ties, or metal folding bars
Envelopes with exposed flap adhesive when the flap is in the closed position
Self-seal envelopes
• Under high-humidity conditions (over 60%), the envelopes may seal during printing.
• For best results, print on new 90 g/m2 (24 lb) sulfite or 25% cotton-bond envelope.
Transparencies
• Use letter (12A5940) or A4-size (12A5941) sheets only.
• Transparencies are only supported in tray 1 (standard or legal trays).
General information
1-13
7100-XXX
Labels
• Labels should be selected using guidelines found in the User's Guide, Complete Printer Guide, or the
Card stock & Label Guide (located at www.lexmark.com), and tested for acceptability.
• Vinyl labels are not supported.
• Labels are only supported in tray 1 (standard or legal trays).
Glossy Paper
• Use letter (12A5950) or A4-size (12A5951) sheets only.
• Glossy paper is only supported from tray 1 (standard or legal trays).
Sensing by source
Input
Paper size
Paper out
Tray present
Integrated 250-sheet
X
X
X
Optional 530-sheet
X
X
X
1-14 Service Manual
7100-XXX
Maintenance approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part.
Use the error code charts, symptom index, and service checks to determine the symptom and repair
the failure. The removals in the repair information chapter may help you identify parts.
•
•
•
•
Printer messages
Symptom tables
Service checks
Repair information
After you complete the repair, perform tests as needed to verify the repair. See “Diagnostic aids” on
page 3-1.
Standard inspection and cleaning procedure
• Switch off printer power, and disconnect the AC power cord from the electrical outlet.
• Remove and inspect the photodevelopers and toner cartridges, shielding them from strong light.
• Inspect the interior of the printer, removing foreign matter such as paper clips, staples, pieces of paper
•
•
•
•
•
•
•
•
•
or transparencies, paper dust, hair, oil, grease, or toner.
Clean the printer interior using a lint-free cloth. Do not use solvents or chemical cleaners to clean the
printer interior.
Use only the specified oil or lubricant on printer parts (some service parts are lubricated at the factory).
Inspect and, if necessary, clean all rubber/plastic rolls with a lint-free cloth. Dry the rolls with a lint-free
cloth.
While cleaning, inspect the interior of the printer for damaged wires, loose connections, toner leakage,
loose springs, and damaged or worn parts.
Be sure the printer is on a single, flat, strong table or desk top.
Inspect all supplies (OCR, cartridges, photodevelopers/toner cartridges, belts, fuser maintenance kits
and paper sources (cassettes, trays, feeders, duplex drawers, finisher, mailbox trays) for obvious
damage and proper installation (paper guides not too tight). Inspect for correct media usage (paper,
transparencies, labels).
Print demo page.
If additional paper sources are installed, print a demo page from each of these (if possible).
Failure to print from an additional tray or feeder may imply one or more pins are bent in the mating
connector.
General information
1-15
7100-XXX
Serial number
Look for serial number information on the right cover and the inside of the front cover of your MFP.
Tools required for service
The removal and adjustment procedures described in this manual require the following tools and
equipment:
•
•
•
•
•
•
•
•
Analog volt ohmmeter (A digital volt ohmmeter may also be used.)
Flat-blade screwdrivers
Needle-nose pliers
#1 Phillips screwdriver
#2 Phillips screwdriver
Slotted screwdriver #1
Slotted clock screwdriver #1
Tweezers, C-ring pliers
When you make voltage readings, always use frame ground unless another ground is specified.
1-16 Service Manual
7100-XXX
Acronyms
ADF
ASIC
BOOTP
CCD
DDNS
DHCP
DPI
DRAM
EP
ESD
FRU
HTTP
HV
HVPS
JBIG
LAN
LASER
LCD
LED
LV
LVPS
MFP
NVRAM
MH
MMR
MR
OEM
PABX
POR
POST
PQET
PSTN
RIP
SMTP
SDRAM
SNMP
TAD
TCP/IP
VAC
VDC
WINS
Automatic document feeder
Application specific integrated circuit
Boot protocol
Charge coupled device
Dynamic domain name service
Dynamic host configuration protocol
Dots per inch
Dynamic random access memory
Electrophotographic process
Electrostatic discharge
Field replaceable unit
Hypertext transport protocol
High voltage
High voltage power supply
Joint Bi-Level Image Experts Group
Local area network
Light amplification by simulated emission of
radiation
Liquid crystal display
Light emitting diode
Low voltage
Low voltage power supply
Multiple function printer
Nonvolatile random access memory
Message handling
Modified modified read
Modem ready
Original equipment manufacturer
Private automatic branch exchange
Power-on reset
Power-on self test
Print quality enhancement technology
Public switched telephone network
Raster image processor
Simple mail transport protocol
Synchronous dynamic random access memory
Simple network management protocol
Telephone answering device
Transmission control protocol Internet protocol
Volts alternating current
Volts direct current
Windows internet name service
General information
1-17
7100-XXX
1-18 Service Manual
7100-XXX
2. Diagnostic information
Start
CAUTION: Remove power from the printer before you connect or disconnect any cable, electronic board or
assembly, for personal safety and to prevent damage to the printer. Always use the hand grips on the side
of the printer and be sure your fingers are not under the printer when you set the printer down.
Use the service error codes, user status messages, user error messages, symptom tables, service checks,
and diagnostic aids, to determine the corrective action necessary to repair a malfunctioning printer.
Service error codes are indicated by a two-character alphanumeric error code. If a service error code
displays, go to the “Service error codes” on page 2-3.
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 Power Saver is invoked, then Power Saver is displayed. If a
user status message displays, go to the “User attendance messages” on page 2-8.
User error messages are indicated by a two- or three-digit error code which provides the user with
information explaining a problem with a print cartridge, paper jam, option, port, and so on. If a user error
message displays, go to the“User attendance messages” on page 2-8.
The User Messages section sometimes allows a servicer to isolate printer problems. This section also gives
actions to be taken when they do not set or clear.
If you have a failing symptom, go to the “Symptom tables” on page 2-11. Locate your symptom, and take
the appropriate action.
If a service error code appears while you are working on the printer, go to the “Service error codes” on
page 2-3 and take the appropriate action.
Diagnostic information
2-1
7100-XXX
Understanding the operator panel
Using the MFP menus
Copy Settings
Paper Select
Sort
Density
Quality
Reduce/Enlarge
Scan Settings
Document Size
Multi Page in A Document
Limitless Scan
Color Compress Ratio
Resolution
Density
Limitation of size of mail
2-2 Service Manual
Machine Settings
Speaker Volume
Paper Settings
Job Timeout
Auto Continue
Toner Saver Mode
Supplies info
Scanner Carriage
Fax Settings
TX Settings
RX Settings
Tray Settings
Delete Document
Comm Settings
Report Settings
Network Settings
Ethernet
IP Configuration
Fax Directory
Quick Dial Entry
Speed Dial Entry
Reports Print
Configuration Page
Activity Report
Memory List
Quick Dial List
Speed Dial List
Scan Directory
Scan Transmission Log
Demo Page
Maintenance Page
Admin Settings
Date /Time Setup
User Settings
TEL Line Type
PBX Selection
PBX Access Digit
Default Mode
Auto Clear
Power Saver
Display Language
Country Code
Setting Default
Admin Menu Lock
7100-XXX
Service error codes
Error code
Action
001 Service Call
Replace the RIP board. See “System board removal” on page 4-36. Or replace
the engine controller board. See“Engine controller board removal” on
page 4-34.
System Board - CPU
002 Service Call
System Board - Flash
003 Service Call
System Board - DRAM
004 Service Call
System Board - RTC
009 Service Call
System Board
005 Service Call
See “Operator panel service check” on page 2-40.
Op Panel
006 Service Call
Scanner Unit
007 Service Call
Printer Communication Error
008 Service Call
Fax Card
C3 Service Call
Engine CTL Board
Scanner unit initialization failed. Home position not found. Possible scanner
calibration failure. See “Flatbed service check” on page 2-41.
Print engine fails to initialize. See “Engine controller board removal” on
page 4-34.
Fax board fails to initialize or fails to respond when a fax is sent. See “Modem / fax
card service check” on page 2-43.
incorrect data is detected in the NVRAM during data confirmation process at
power-on.
1. POR the machine.
2. If problem persists, replace the controller board.
C4 Service Call
Engine CTL Board
Defective engine controller board is causing faulty data transmission between ASIC
and CPU.
POR the printer. If error still exists, replace the engine controller board. See
“Engine controller board removal” on page 4-34.
C7 Service Call
Synchronization signal from main motor is not detected.
Main Motor
See “Main motor service check” on page 2-14.
D4 Service Call
See “Low voltage power supply (LVPS) service check” on page 2-23.
LV Power Supply
E0 Service Call
An over-current signal is detected due to an abnormal load on developer motor 1.
Developer Motor 1 - MK
1. Replace black and magenta toner cartridge.
2. If error persists, see “Developer drive assembly service check” on
page 2-16.
E1 Service Call
An over-current signal is detected due to an abnormal load on developer motor 2.
Developer Motor 2 - CY
1. Replace yellow and cyan toner cartridge.
2. If error persists, see “Developer drive assembly service check” on
page 2-16.
Diagnostic information
2-3
7100-XXX
Error code
Action
E2 Service Call
A NOT READY signal (rotation error signal) is detected because of abnormal main
motor rotation.
Main Motor
See “Main motor service check” on page 2-14.
E3 Service Call
Unstable transfer belt rotation–color matching cannot be secured.
Transfer Belt Sensor
See “Transfer belt unit service check” on page 2-17.
E5 Service Call
Improper transfer roller clutch cable connection or a shorted or cut cable.
Transfer Roller Clutch
See “Transfer roller clutch service check” on page 2-18.
E6 Service Call
Improper cleaning roller clutch cable connection or a shorted or cut cable.
Transfer Cleaner Solenoid
See “Transfer belt cleaning roller clutch service check” on page 2-18.
E7 Service Call
Improper paper-feed clutch cable connection or a shorted or cut cable.
P feed Clutch Tray 1
See “Paper feed clutch service check” on page 2-19.
E8 Service Call
Improper registration clutch cable connection or a shorted or cut cable.
Registration Clutch
See “Registration clutch service check” on page 2-19.
E9 Service Call
Marker sensor is not properly detecting mark on OPC belt.
OPC Marker Sensor
See “OPC belt marker sensor service check” on page 2-20.
EL Service Call
Improper erase lamp cable connection or a shorted or cut cable.
Erase Lamp
Erase lamp LED terminal may be cut.
See “Erase lamp service check” on page 2-21.
F0 Service Call
Power Supply Fan
Improper fan motor rotation, improper fan motor cable connection or a shorted or
cut cable.
See “Power supply fan service check” on page 2-22.
F4 Service Call
Fuser Fan
Improper fan motor rotation, improper fan motor cable connection or a shorted or
cut cable.
See “Fuser fan service check” on page 2-22.
F5 Service Call
HV Power Supply Unit
Output (BRV) of HVPS is shorted, and or HVPS cable connector is improperly
connected.
See “High voltage power supply (HVPS) service check” on page 2-23.
F6 Service Call
Data communication error between LVPS and the engine controller board.
LV Power Supply Unit
See “Low voltage power supply (LVPS) service check” on page 2-23.
H0 Service Call
Temperature signal from thermistor is not detected.
Fuser Unit
See “Fuser thermistor service check” on page 2-24.
H1 Service Call
Circuitry that controls the fuser temperature has failed.
Fuser Unit
See “Fuser assembly service check” on page 2-24.
H2 Service Call
Fusing temperature is not reached within the warming-up time period.
Fuser Unit
See “Fuser assembly service check” on page 2-24.
H3 Service Call
Fusing temperature drops below fusing threshold during the printing process and
does not reach fusing temperature again within alloted time.
Fuser Unit
See “Fuser assembly service check” on page 2-24.
2-4 Service Manual
7100-XXX
Error code
Action
H4 Service Call
Fusing temperature rises above limit during printing process and does not return
within the alloted time period.
Fuser Unit
See “Fuser assembly service check” on page 2-24.
HA Service Call
AC relay turned off due to an abnormal temperature.
Fuser Unit
See “Fuser assembly service check” on page 2-24.
L1 Service Call
Laser scanning beam is not detected by beam sensor.
Laser Unit Assembly
See “Laser unit assembly service check” on page 2-25.
L2 Service Call
Scanner motor (SM) is rotating abnormally.
Laser Unit Assembly
See “Laser unit assembly service check” on page 2-25.
LL Service Call
Laser power is lower than the output limit.
Laser Unit Assembly
See “Laser unit assembly service check” on page 2-25.
N3 Service Call
Improper connection between engine controller board and HVPS.
HVPS Connection
See “HVPS connection service check” on page 2-25.
N4 Service Call
Improper connection between engine controller board and toner sensor sender
board.
Toner Empty Sensor
See “Toner empty sensor (sender-TPD) service check” on page 2-26.
N5 Service Call
Toner Empty Rcv
Improper connection between engine controller board and toner sensor receiver
board.
See “Toner empty sensor (receiver-TTR) service check” on page 2-27.
N6 Service Call
Improper connection between engine controller board and lower paper feed unit.
LFU Connection
See “Lower feed unit (secondary paper assembly) service check” on
page 2-28.
P6 Service Call
Data communication error between engine controller board and LFU paper-feed
clutch.
Pfeed Clutch Tray 2
See “Lower feed unit (secondary paper assembly) service check” on
page 2-28.
Diagnostic information
2-5
7100-XXX
User status messages
Message
Description
Action
Tray (1, 2) Missing
The upper or lower tray is
missing.
install the upper or lower tray. If the problem
persists, see “Paper tray missing service
check” on page 2-30.
Toner Low (C,M,Y,K)
The toner is low in the
cartridge indicated.
See “Toner low/empty service check” on
page 2-31.
Sleep
The MFP is idle.
These are the normal operating modes.
Please Wait
The MFP is warming up.
READY
The MFP is ready to
perform a task.
PC Printing
The MFP is printing.
Calibrating
The MFP is calibrating.
Connected to Server
The MFP is connected to
a server for a push scan
job.
Sending File...
A scan job is being
transmitted.
Send E-mail Notification
An e-mail is being sent to
a user notifying them of a
push scan job being
completed.
Connection Fail
Unable to connect to the
remote fax.
No Response
The device
Busy
The remote fax device is
currently busy.
Dial Failed
The dial attempt to
another device failed.
Scanning Page
The scanner is scanning
in the flatbed or ADF.
Job #
Fax Job # is being
processed.
Dialing
A fax number is being
dialed.
Awaiting Re dial
The fax is between dialing
attempts.
Transmitting
The fax is transmitting
data to another fax
device.
Receiving
The X502 is receiving fax
data from a remote fax
device.
2-6 Service Manual
7100-XXX
Message
Description
Action
TAD Answering
A telephone call is being
received.
These are the normal operating modes.
Answering
The fax is answering an in
coming call.
incoming Call
There is an incoming call
on the phone line
Warming Up
The MFP is warming up.
Diagnostic information
2-7
7100-XXX
User attendance messages
Message
Description
Action
Paper Empty
The upper or lower paper
tray is empty or the media
in the trays is inconsistent.
Fill up the paper tray(s) or replace the media with
the correct type. If the problem persists, see
“Tray empty service check” on page 2-29.
(Load Tray - Paper Size, Load
Tray 1 Paper Size, Load Tray 2
Paper Size, Load Tray Paper)
Paper Change
Media size and type
mismatch.
Load Paper <Type, Size>
Paper Error
• Check the media size.
• Check the media size setting in the cassette.
• Check to make sure the media setting on the
printer and drive match the media in the
cassette.
Media type mismatch.
Load the paper tray with the correct media type.
Tray (1, 2) Missing
The upper or lower tray is
missing.
install the upper or lower tray. If the problem
persists, see “Paper tray missing service
check” on page 2-30.
Toner Low (C,M,Y,K)
The toner is low in the
cartridge indicated.
See “Toner low/empty service check” on
page 2-31.
C/M/Y/K Toner Empty
The specific toner
cartridge needs to be
replaced. in most cases,
only one of the letters
CYMK will appear.
install the appropriate toner cartridge. If problem
persists, see “Toner low/empty service check”
on page 2-31.
Waste Pack Full
The waste toner bottle is
full or not installed.
install the waste toner bottle or replace the full
waste toner bottle. If problem persists, see
“Waste toner bottle service check” on
page 2-31.
OPC Exhausted
Replace with a new OPC
unit.
See “Photodeveloper cartridge removal” on
page 4-8.
Replace with a new OPC
unit.
See “Photodeveloper cartridge removal” on
page 4-8.
Replace with a new fuser
unit.
See “Fuser assembly removal” on page 4-6.
Replace with a new
transfer belt unit.
See “Transfer belt unit removal” on page 4-5.
The fuser is not installed.
If fuser is installed, remove it and reinstall. If
problem persists, check the cable that connects
engine controller board connector FUCN and
fuser. If the cable is bad, replace the cable.
Otherwise, replace the engine controller board.
See “Engine controller board removal” on
page 4-34.
Load Tray 1 <Paper Type>
Replace Toner C/M/Y/K
Replace OPC Belt
OPC Belt Life
Replace OPC Belt
Fuser Life
Replace Fuser
TR Belt Life
Replace Transfer Belt
Missing
install Fuser Unit
2-8 Service Manual
7100-XXX
Message
Description
Action
Toner Error
An invalid toner cartridge
is installed.
install a supported cartridge. If the problem
persists, see “Missing toner cartridge service
check” on page 2-32.
A toner cartridge is not
keyed properly.
install proper brand of toner cartridge. If problem
persists, see “Missing toner cartridge service
check” on page 2-32.
The OPC belt cartridge is
not installed.
Correctly install the photodeveloper cartridge to
clear message and continue printing. If error
persists, see “Missing photodeveloper
cartridge service check” on page 2-33.
The transfer roller is not
installed.
Ensure transfer roller is properly installed. If
problem persists, see “Transfer roller missing
service check” on page 2-34.
Paper Jam A 1-2
Paper is jamming at
feeding area.
See “Paper Jam A1, rear (tray 1)” on page 3-24
or “Paper Jam A2, rear (tray 2)” on page 3-26
for instructions to clear the jam.
Paper Jam B
Paper is jamming inside
the MFP.
See “Paper Jam B rear” on page 3-27 for
instructions to clear the jam.
Paper Jam C
Paper is jamming at paper
exit area.
See “Paper Jam C rear” on page 3-29 for
instructions to clear the jam.
Cover Open
The back, front, or OPC
cover is open.
Close specified cover if open. If not open, open
the cover and close. If the problem persists, see
“Cover open service check” on page 2-35.
The transfer belt is at its
end of life.
Replace the transfer belt. See “Transfer belt unit
removal” on page 4-5.
The transfer roll and
transfer belt cleaning roll
have reached the end of
life.
Replace the transfer roll. See “Transfer roller
removal” on page 4-6. Also, replace the transfer
belt cleaning roller. See “Transfer belt cleaning
roller removal” on page 4-4.
The paperfeed roll and
separator pad in tray 1 are
at the end of life.
Replace the paperfeed roll and the separator pad
for the respective paper tray (1 or 2). See “Paper
feed roller removal” on page 4-32.
install Supported Cartridge
Missing
install Toner (C,M,Y,K)
Missing
install OPC Belt
Missing
install Transfer Roller
Close (Front, Rear, OPC)
TR Belt Life
Replace Transfer Belt
TR Kit Life
Replace PQ Kit
PF1 Kit Life
Replace PF Kit 1
PF2 Kit Life
Replace PF Kit 2
ADF Jam
The paperfeed roll and
separator pad in tray 2 are
at the end of life.
A sheet of paper is
jammed in the ADF.
Clear the ADF jam. If the message persists, see
“ADF streak service check” on page 2-41.
The ADF cover is open.
Close the ADF cover. If the cover is already
closed, see “ADF streak service check” on
page 2-41.
Scan Calibration Error
Scanner is out of
calibration.
Perform scanner calibration.
Scan Lock Error
The scanner lock is in the
locked position.
Unlock the scanner. If the scanner lock is in the
unlocked position, see “Flatbed service check”
on page 2-41.
Open ADF cover and Clear Jam
ADF Cover Open
Close ADF cover
Unlock Scanner
Diagnostic information
2-9
7100-XXX
Message
Description
Action
Scan USB Disconnect
The USB connection is
disconnected.
See “USB service check” on page 2-40.
Scan Network Disconnect
The network connection is
disconnected.
See “Network service check” on page 2-40.
Duplicate IP Address Found
Another device using an
identical IP address has
been detected on the
network.
Contact the network administrator.
E-mail Size Limit Exceeded
E-mail memory buffer full.
Retry the job. Break it up if needed.
Out of Memory
Memory depleted.
Retry the print job. Break it up if needed.
Scan Memory Full
Memory for the scan job is
full.
Break the scan job into smaller segments.
Communication Error
Communication with host
machine failed.
Retry the job. Check all connections with the host
device.
Server Connection Failed
Communications with the
server failed.
Retry the job. Check all connections with the host
device.
(TX / RX) Comm Error
There is a data
transmission or reception
error.
Resend the fax.
CPU fan locked
The CPU fan is no longer
running on the RIP card.
See “CPU fan service check” on page 2-16.
Note: The expected yield of the separator pad and paperfeed roll are 120,000 pages.
2-10 Service Manual
7100-XXX
Symptom tables
MFP symptom table
Symptom
Action
Paper feed problems
See “Paper feed service checks” on page 2-44.
Close door displayed when all doors are closed.
See “User attendance messages” on page 2-8, and
follow the action suggested.
Paper jam messages do not reset after removing
paper.
See “User attendance messages” on page 2-8, and
follow the action suggested.
Toner cartridge does not turn or does not put toner on
the photodeveloper cartridge.
See “Toner feed service check” on page 2-39.
Developer motor makes noise or continuously runs.
See “Developer drive assembly service check” on
page 2-16.
Main motor makes noise or continuously runs.
See “Main motor service check” on page 2-14.
Transfer belt unit makes noise when rotated or does
not rotate at all.
See “Transfer belt unit service check” on page 2-17.
The transfer roll is not transferring images or does not
turn.
See “White band service check” on page 2-63.
No power
See “Printer no power service check” on page 2-38.
Waste toner feed problems
See “Waste toner feed service check” on page 2-39.
Fans not working or making noise.
See “Service error codes” on page 2-3. Find the failing
fan, and follow the action suggested.
Print/image problems
See “Print quality symptom table” on page 2-13.
Photodeveloper cartridge does not rotate or makes
noise.
See “OPC belt (photodeveloper) cartridge drive service
check” on page 2-36.
Black copies from scanner.
See “Black page copy service check” on page 2-41.
Fail to scan from the flatbed.
See “Flatbed service check” on page 2-41.
Paper jams in the ADF.
See “ADF paper feed service check” on page 2-42.
Paper skews when fed into the ADF.
See “ADF paper feed service check” on page 2-42.
Paper fails to feed into the ADF.
See “ADF paper feed service check” on page 2-42.
Op panel failure
See “Operator panel service check” on page 2-40.
Fax fails to transmit.
See “Modem / fax card service check” on page 2-43.
Fax appears stretched or compressed.
Issue with sending fax machine.
Streaks down the middle of a copy, fax or scan when
using the ADF
See “ADF streak service check” on page 2-41.
Scanner locked
Check the scanner lock switch. If it is unlocked see
“Flatbed service check” on page 2-41.
Scanner fails to communicate with the host PC.
If the MFP is USB-attached, see “USB service check” on
page 2-40. If the MFP is network-attached, see “Network
service check” on page 2-40.
Diagnostic information
2-11
7100-XXX
Symptom
Action
No dial tone when sending a fax.
See “Modem / fax card service check” on page 2-43.
Lines on outbound fax documents
Check the flatbed glass for scratches or marks.
Words and images on inbound fax documents are
stretched out.
The sending machine had a temporary jam.
2-12 Service Manual
7100-XXX
Print quality symptom table
Symptom
Action
Background
See “Background service check” on page 2-45.
Missing image at edge
See “Missing image at edge service check” on page 2-53.
Jitter
See “Jitter service check” on page 2-52.
Ribbing
See “Ribbing service check” on page 2-57.
Wrinkle and image migration
See “Wrinkle / image migration service check” on page 2-67.
White line
See “White line II service check” on page 2-64.
White line
See “White line II service check” on page 2-64.
Vertical white band
See “Vertical white band service check” on page 2-62.
Black line
See “Black line service check” on page 2-48.
Vertical line
See “Vertical line service check” on page 2-60.
Vertical staggering image
See “Vertical staggering image service check” on page 2-61.
Banding
See “Banding service check” on page 2-47.
White band
See “White band service check” on page 2-63.
Toner drop
See “Toner drop service check” on page 2-59.
White spots and black spots
See “White spot / black spot service check” on page 2-65.
Mixed color image
See “Mixed color image service check” on page 2-54.
Color misregistration
See “Color misregistration service check” on page 2-49.
Mottle
See “Mottle service check” on page 2-55.
Residual image
See “Residual image service check” on page 2-56.
Insufficient gloss
See “insufficient gloss service check” on page 2-51.
Back stain
See “Back stain service check” on page 2-46.
White print
See “White print service check” on page 2-66.
Insufficient fusing
See “insufficient fusing service check” on page 2-50.
Diagnostic information
2-13
7100-XXX
Printer service checks
Main motor service check
Step
Questions / actions
1
Turn printer off and remove right cover. See
“Right cover removal” on page 4-13.
Open top cover and override top cover
interlock switch. Restart printer, and observe
main motor and photodeveloper cartridge
OPC belt. Does main motor attempt to turn
but OPC belt will not rotate?
Replace photodeveloper
cartridge.
Observe main motor and fuser. Does main
motor attempt to turn but fuser will not?
Replace fuser assembly.
See “Fuser assembly
removal” on page 4-6.
2
Yes
No
Go to step 2.
Note: photodeveloper
cartridge is a customerordered supply.
Go to step 3.
Note: Fuser is a customerordered supply.
3
Are there any unusual noises around main
motor before error posts?
Replace main motor. See
“Main motor assembly
removal” on page 4-26.
Go to step 4.
Go to step 5.
4
Does noise go away?
Problem solved.
Go to step 5.
5
Is cable properly connected to main motor?
Go to step 6.
Properly connect cable.
Retest printer. If error
clears, problem solved,
otherwise go to step 6.
6
If waste toner bottle is removed, reinsert it.
Ensure rear cover assembly cover is shut.
Override top and front cover interlock
switches. For location, see “Fan/motor and
interlock switch locations” on page 5-6.
Reconnect operator panel. Turn printer on.
Allow printer to run until error posts.
Disconnect connector from main motor, and
check the following on disconnected cable
connector:
Replace main motor. See
“Main motor assembly
removal” on page 4-26.
Go to step 9.
Go to step 7.
Go to step 8.
Replace cable. Retest
printer. If error clears,
problem solved, otherwise
go to step 8.
Pin 4 to pin 5–24VDC
Pin 6 to pin 5–24VDC
Pin 10 to pin 5–5VDC
Are voltages present?
7
Remove engine controller board shield. See
“Engine controller board removal” on
page 4-34 for steps to remove engine
controller board shield. Disconnect MCN5
from engine controller board. Check for
continuity and shorted pins on cable that
connects MCN5 to main motor. Is cable
okay?
2-14 Service Manual
7100-XXX
Step
8
Questions / actions
Disconnect cable from engine controller
board POCN. Check the following on
disconnected cable connector:
Yes
No
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34. Go step 9.
Replace cable that
connects ACN1 on LVPS to
POCN on engine controller
board. Remove RIP board
cage to gain access to
cable. See “System board
cage removal” on
page 4-39. Go to step 9.
Problem solved.
Contact next level of
support.
Pin 21 to pin 22–24VDC
Pin 13 to pin 14–5VDC
Are voltages present?
9
Reassemble and retest printer. Does error
clear?
Diagnostic information
2-15
7100-XXX
CPU fan service check
Step
Questions / actions
Yes
No
1
Open the RIP cage cover. Is the CPU fan
spinning?
No issue to fix.
Go to step 2.
2
Is the CPU fan cable properly connected to
J-Fan1 on the RIP board?
Connect the cable to JFan1.
Replace the RIP board. See
“System board removal”
on page 4-36.
Developer drive assembly service check
Step
Questions / actions
Yes
No
1
Are there any unusual noises heard around
developer motor or developer drive
assembly before error posts?
Replace toner cartridge
(customer-ordered supply).
Go to step 2.
Go to step 4.
2
Does noise go away?
Problem solved.
Replace developer drive
assembly. See “Developer
drive assembly removal”
on page 4-22. Go to step 3.
3
Does noise go away?
Problem solved.
Go to step 4.
4
Turn printer off, and remove right cover. See
“Right cover removal” on page 4-14. Is
cable properly connected to developer drive
assembly motor?
Go to step 5.
Properly connect cable.
Retest printer. If error
clears, problem solved,
otherwise go to step 5.
5
If waste toner bottle is removed, reinsert it.
Ensure rear cover assembly is shut.
Override top and front cover interlock
switches. For location, see “Interlock
switch locations” on page 5-6. Reconnect
operator panel. Turn printer on. Allow printer
to run until error posts. Disconnect
connector from each developer motor, and
check for the following on each
disconnected cable connector:
Replace developer drive
assembly. See “Developer
drive assembly removal”
on page 4-21. Go to step 8.
Go to step 6.
Go to step 7.
Replace cable. Retest
printer. If error clears,
problem solved, otherwise
go to step 7.
Pin 2 to ground–24VDC
Pin 5 to ground–24VDC
Are voltages present?
6
Remove engine controller board shield. See
“Engine controller board removal” on
page 4-34 for steps to remove engine
controller board shield. Disconnect MCN5
from engine controller board. Check for
continuity and shorted pins on cable that
connects MCN5 to developer motors. Is
cable okay?
2-16 Service Manual
7100-XXX
Step
7
Questions / actions
Disconnect cable from engine controller
board POCN. Check the following on
disconnected cable connector:
Yes
No
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34. Go step 8.
Replace cable that
connects ACN1 on LVPS to
POCN on engine controller
board. Remove RIP board
cage to gain access to
cable. See “System board
cage removal” on
page 4-39. Go to step 8.
Problem solved.
Contact next level of
support.
Pin 21 to pin 22–24VDC
Pin 13 to pin 14–5VDC
Are voltages present?
8
Reassemble and retest printer. Does error
clear?
Transfer belt unit service check
Step
Questions / actions
Yes
No
1
Open rear cover assembly, and check
transfer belt unit markers for stains. Are
markers stained?
Clean belt marker area with
cotton cloth. If problem
persists, go to step 2.
Go to step 2.
2
Remove transfer belt unit, and observe
markers on side. Are belt markers deformed
or does transfer belt seem hard to rotate?
Replace transfer belt unit.
See “Transfer belt unit
removal” on page 4-5.
Reinstall transfer belt unit.
Go to step 3.
3
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Are cables properly connected to
engine controller board connectors MCN9
and POCN?
Go to step 4.
Properly connect cables. If
problem persists, go to step
4.
4
Ensure rear cover assembly and front cover
assembly are closed. Override top interlock
switch, and turn printer on. Wait until printer
displays error, and remove MCN9 from
engine controller board. Check for 5 VDC
between MCN9 pin 1 (on engine controller
board) and ground (you can touch negative
lead of voltmeter to metal frame to obtain
ground.) Is voltage present and correct?
Engine controller board is
providing 5 VDC to marker
sensor. Replace transfer
belt marker sensor. Marker
sensor is part of a bracket
assembly. See “Bracket
assembly removal” on
page 4-30. If problem
persists, replace engine
controller board. See
“Engine controller board
removal” on page 4-34.
Go to step 5.
5
On engine controller board, reconnect
MCN9 and disconnect cable from POCN.
On cable disconnected from POCN, check
for 5 VDC from pin 13 to ground (you can
touch negative lead of voltmeter to metal
frame to obtain ground.) Is voltage present
and correct?
LVPS is providing 5 VDC to
engine controller board.
Replace faulty engine
controller board. See
“Engine controller board
removal” on page 4-34.
Replace LVPS. See “Low
voltage power supply
(LVPS) with cage
removal” on page 4-41.
Diagnostic information
2-17
7100-XXX
Transfer roller clutch service check
Step
Questions / actions
Yes
No
1
Turn printer off and remove printer right
cover. See “Right cover removal” on
page 4-13. Is cable properly connected to
transfer roller clutch?
Go to step 2.
Properly connect cable. If
problem persists, go to step
2.
2
Disconnect transfer roller clutch from cable.
Measure resistance between two outer pins
on transfer roller clutch. Does resistance
measure between 119 and 145 ohms?
Go to step 3.
Replace faulty transfer
roller clutch. See “Clutch
removal” on page 4-27.
3
Remove engine controller board shield. See
“Engine controller board removal” on
page 4-34 for steps to remove engine
controller board shield. Disconnect cable
from MCN4 on engine controller board.
Check cable continuity from MCN4 pins 5
and 6 (cable) to connector that attaches to
transfer roller clutch. Ensure that pins are
not shorted. Is cable okay?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34. If problem
persists, replace faulty
transfer roller clutch. See
“Clutch removal” on
page 4-27.
Replace cable. If problem
persists, replace faulty
transfer roller clutch. See
“Clutch removal” on
page 4-27.
Transfer belt cleaning roller clutch service check
Step
Questions / actions
Yes
No
1
Turn printer off, and remove printer right
cover. See “Right cover removal” on
page 4-13. Is cable properly connected to
cleaning roller clutch?
Go to step 2.
Properly connect cable. If
problem persists, go to step
2.
2
Disconnect transfer belt cleaning roller
clutch from cable. Measure resistance
between two outer pins on cleaning roller
clutch. Does resistance measure between
198 and 242 ohms?
Go to step 3.
Replace faulty cleaning
roller clutch. See
“Cleaning roller clutch
removal” on page 4-25.
3
Remove engine controller board shield. See
“Engine controller board removal” on
page 4-34 for steps to remove shield.
Disconnect cable from MCN4 on engine
controller board. Check cable continuity
from MCN4 pins 1 and 2 (cable) to
connector that attaches to cleaning roller
clutch. Ensure that pins are not shorted. Is
cable okay?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34. If problem
persists, replace faulty
cleaning roller clutch. See
“Cleaning roller clutch
removal” on page 4-25.
Replace cable. If problem
persists, replace faulty
cleaning roller clutch. See
“Cleaning roller clutch
removal” on page 4-25.
2-18 Service Manual
7100-XXX
Paper feed clutch service check
Step
Questions / actions
Yes
No
1
Turn printer off, and remove printer right
cover. See “Right cover removal” on
page 4-13. Is cable properly connected to
paper feed clutch?
Go to step 2.
Properly connect cable. If
problem persists, go to step
2.
2
Disconnect paper feed clutch from cable.
Measure resistance between two outer pins
on paper feed clutch. Does resistance
measure between 119 and 145 ohms?
Go to step 3.
Replace faulty paper feed
clutch. See “Clutch
removal” on page 4-27.
3
Remove engine controller board shield. See
“Engine controller board removal” on
page 4-34 for steps to remove engine
controller board shield. Disconnect cable
from MCN4 on engine controller board.
Check cable continuity from MCN4 pins 9
and 10 (cable) to outer pins on connector
that attaches to paper feed clutch. Ensure
that pins are not shorted. Is cable okay?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34. If problem
persists, replace faulty
paper feed clutch. See
“Clutch removal” on
page 4-27.
Replace cable. If problem
persists, replace faulty
paper feed clutch. See
“Clutch removal” on
page 4-27.
Registration clutch service check
Step
Questions / actions
Yes
No
1
Turn printer off, and remove printer right
cover. See “Right cover removal” on
page 4-13. Is cable properly connected to
registration clutch?
Go to step 2.
Properly connect cable. If
problem persists, go to step
2.
2
Disconnect registration clutch from cable.
Measure resistance between two outer pins
on paper feed clutch. Does resistance
measure between (****check these values)
119 and 145 ohms?
Go to step 3.
Replace registration clutch.
See “Clutch removal” on
page 4-27.
3
Remove engine controller board shield. See
“Engine controller board removal” on
page 4-34 for steps to remove engine
controller board shield. Disconnect cable
from MCN4 on engine controller board.
Check cable continuity from MCN4 pins 7
and 8 (cable) to outer pins on connector that
attaches to registration clutch. Ensure that
pins are not shorted. Is cable okay?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34. If problem
persists, replace faulty
registration clutch. See
“Clutch removal” on
page 4-27.
Replace cable. If problem
persists, replace faulty
registration clutch. See
“Clutch removal” on
page 4-27.
Diagnostic information
2-19
7100-XXX
OPC belt marker sensor service check
Step
Questions / actions
Yes
No
1
Remove photodeveloper cartridge and
check for defects. Does photodeveloper
appear okay?
Go to step 2.
Replace photodeveloper
cartridge.
2
Observe markers on side. Are belt markers
covered with foreign particles?
Clean marker area with
cotton cloth. If problem
persists, go to step 3.
Go to step 3.
3
Reinstall photodeveloper cartridge. Turn
printer off, and remove engine controller
board shield. See “Engine controller
board removal” on page 4-34 for steps to
remove engine controller board shield. Is
cables MCN7 properly connected to engine
controller board?
Go to step 3.
Properly connect cable. If
problem persists, go to step
4.
4
Ensure rear cover assembly and front cover
assembly are closed. Override top interlock
switch, and turn printer on. Wait until printer
displays error, and remove MCN7 from
engine controller board. Check for 5 VDC
between MCN7 pin 3 (on engine controller
board) and ground (you can touch negative
lead of voltmeter to metal frame to obtain
ground.) Is voltage present and correct?
Engine controller board is
providing 5 VDC to OPC
sensor. Replace OPC
marker sensor. See
“Marker sensor assembly
removal” on page 4-47. If
problem persists, replace
engine controller board.
See “Engine controller
board removal” on
page 4-34.
Go to step 5.
5
Reconnect MCN7, and disconnect cable
from POCN. On disconnected cable, check
for 5 VDC on cable pin corresponding to
POCN pin 13. You can touch negative lead
of voltmeter to metal frame to obtain ground.
Is voltage present and correct?
LVPS is providing 5 VDC to
engine controller board.
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Go to step 6.
6
Turn printer off. Disconnect cable that
connects LVPS ACN1 to engine controller
board POCN, and check for continuity,
shorted pins, or any other cable damage. Is
cable okay?
Replace LVPS. See “Low
voltage power supply
(LVPS) with cage
removal” on page 4-41.
Replace cable.
2-20 Service Manual
7100-XXX
Erase lamp service check
Step
Questions / actions
Yes
No
1
Turn printer off, and remove toner cartridges
and photodeveloper cartridge. Check erase
lamp cable for proper connection. Is erase
lamp cable properly connected?
Go to step 2.
Properly connect erase
lamp. Retest printer. If error
clears, problem solved,
otherwise go to step 2.
2
Check erase lamp for any visible damage. Is
erase lamp damaged?
Replace erase lamp. See
“Erase lamp removal” on
page 4-20. Retest printer. If
error clears, problem
solved, otherwise remove
toner cartridges and
photodeveloper cartridge
and go to step 3.
Go to step 3.
3
Set multimeter to check diodes. Looking at
erase lamp through front cover, touch meter
positive lead to left LED connection and
meter negative lead to right LED
connection. LED should illuminate. Check
all LEDs on erase lamp board. Do any LEDs
fail to illuminate?
Replace erase lamp. See
“Erase lamp removal” on
page 4-20. Retest printer. If
error clears, problem
solved, otherwise go to step
4.
Go to step 4.
4
Remove engine controller board shield. See
“Engine controller board removal” on
page 4-34 for steps to remove engine
controller board shield. Is cable properly
connected to engine controller board
connector MCN8?
Go to step 5.
Properly connect cable.
Retest printer. If error
clears, problem solved,
otherwise go to step 5.
5
Disconnect cable from erase lamp and
engine controller board MCN8. Check for
continuity between cable pin that
corresponds to MCN8 pin 11 and erase
lamp cable connector pin 3. Also check for
continuity between cable pin that
corresponds to MCN8 pin 12 and erase
lamp cable connector pin 1. Check for
shorted pins on both sides of cable. Is cable
okay?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34. Go to step 6.
Replace cable. Retest
printer. Go to step 6.
6
Retest printer. Does error clear?
Problem solved.
Contact higher level
support.
Diagnostic information
2-21
7100-XXX
Power supply fan service check
Step
Questions / actions
Yes
No
1
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Is cable properly connected to
engine controller board connector MCN10?
Go to step 2.
Properly connect cable.
2
Ensure rear cover assembly cover is shut.
Override top and front cover interlock
switches. For location, see “Fan/motor and
interlock switch locations” on page 5-6.
Turn printer on, and check for 24VDC
between engine controller board MCN10
pin 1 and power ground (you can touch
negative lead of voltmeter to metal frame to
obtain ground.) Is voltage present and
correct?
Replace power supply fan
assembly. See “Power
supply fan removal” on
page 4-49. Retest printer. If
error clears, problem
solved, otherwise go to step
3.
Go to step 3.
3
Turn printer off, and disconnect cable from
engine controller board MCN10 and power
supply fan. Check cable for continuity and
pin shorts. Is cable okay?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Replace cable.
Fuser fan service check
Step
Questions / actions
1
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Is cable properly connected to
engine controller board connector MCN1?
Go to step 2.
Properly connect cable.
2
Ensure rear cover assembly cover is shut.
Override top and front cover interlock
switches. For location, see “Fan/motor and
interlock switch locations” on page 5-6.
Reconnect operator panel. Turn printer on,
and check for 24VDC between engine
controller board MCN1 pin 4 and power
ground (you can touch negative lead of
voltmeter to metal frame to obtain ground.)
Is voltage present and correct?
Potentially faulty fuser fan.
Replace rear cover
assembly. See “Rear cover
assembly removal” on
page 4-14. Retest printer. If
error clears, problem
solved, otherwise go to step
3.
Go to step 3.
3
Turn printer off, and disconnect cable from
engine controller board MCN1 and power
supply fan. Check cable for continuity and
pin shorts. Is cable okay?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Replace cable.
2-22 Service Manual
Yes
No
7100-XXX
High voltage power supply (HVPS) service check
Step
Questions / actions
1
Remove photodeveloper cartridge,
and ensure charging unit on bottom
of photodeveloper cartridge is not
damaged. Is charging unit
damaged?
Yes
No
Replace photodeveloper
cartridge. See
“Photodeveloper cartridge
removal” on page 4-8.
Go to step 2.
Note: photodeveloper
cartridge is a customerordered part.
2
Check charging unit high voltage
contacts in printer. Are they clean?
Go to step 3.
Clean contacts. If problem
persists, go to step 3.
3
Replace photodeveloper cartridge.
See “Photodeveloper cartridge
removal” on page 4-8. Has error
cleared?
Problem solved.
Go to step 4.
Note: photodeveloper cartridge is a
customer-ordered part.
4
Check cable for continuity between
engine controller board connector
HVCN and HVPS BCN1 connector
and for shorted pins. Is cable okay?
Go to step 5.
Replace cable.
5
Replace HVPS. See “High voltage
power supply (HVPS) removal” on
page 4-40. Has error cleared?
Problem solved.
Go to step 6.
6
Replace engine controller board.
See “Engine controller board
removal” on page 4-34. Has error
cleared?
Problem solved.
Contact higher level support.
Low voltage power supply (LVPS) service check
Step
Questions / actions
Yes
No
1
Check cable for continuity between engine
controller board connector LVCN and LVPS
ACN4 connector. Also check for shorted
pins. Is cable okay?
Go to step 2.
Replace cable.
2
Replace LVPS. See “Low voltage power
supply (LVPS) with cage removal” on
page 4-41. Does problem persist?
Go to step 3.
Problem solved.
3
Replace engine controller board. See
“Engine controller board removal” on
page 4-34. Does problem persist?
Contact higher level
support.
Problem solved.
Diagnostic information
2-23
7100-XXX
Fuser thermistor service check
Step
Questions / actions
Yes
No
1
Remove and reinstall fuser assembly. See
“Fuser assembly removal” on page 4-6.
Does error clear?
Problem solved.
Go to step 2.
2
Check fuser connector for damage.
Replace if necessary. Does error clear?
Problem solved.
Go to step 3.
3
Turn printer off, and check cable that
connects engine controller board connector
FUCN to fuser for proper connection,
continuity, and pin shorts. Is cable okay?
Go to step 4.
Properly connect cable or
replace if damaged. If error
clears, problem solved,
otherwise go to step 4.
4
Replace fuser assembly. See “Fuser
assembly removal” on page 4-6. Does
error clear?
Problem solved.
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Note: Fuser is a customer order supply.
Fuser assembly service check
Step
Questions / actions
Yes
No
1
Check for proper input line voltage. Is line
voltage correct?
Go to step 2.
Provide proper line voltage.
2
Remove and reinstall fuser assembly. See
“Fuser assembly removal” on page 4-6.
Does error clear?
Problem solved.
Go to step 3.
3
Check fuser connector for damage. Replace
if necessary. Does error clear?
Problem solved.
Go to step 4.
4
Turn printer off, and check cable that
connects engine controller board connector
FUCN to fuser for proper connection,
continuity, and pin shorts. Is cable okay?
Go to step 5.
Properly connect cable or
replace if damaged. If error
clears, problem solved,
otherwise go to step 5.
5
Replace fuser assembly. See “Fuser
assembly removal” on page 4-6. Does
error clear?
Problem solved.
Replace LVPS. See “Low
voltage power supply
(LVPS) with cage
removal” on page 4-41. If
error does not clear,
replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Note: Fuser is a customer-ordered supply.
2-24 Service Manual
7100-XXX
Laser unit assembly service check
Step
Questions / actions
Yes
No
1
Check LCN connection on laser assembly
LDU board. Is connector properly
connected?
Go to step 2.
Properly connect LCN
cable. If error clears,
problem solved, otherwise
go to step 2.
2
Check LCN connection on engine controller
board. Is cable properly connected?
Go to step 3.
Properly connect LCN
cable. If error clears,
problem solved, otherwise
go to step 3.
3
Check cable that connects engine controller
board LCN and LDU LCN connectors for
continuity and shorted pins. Is cable okay?
Replace laser unit
assembly. “Upper right
rear cover removal” on
page 4-17. Go to step 4.
Replace cable. Go to step
4.
4
Does error clear?
Problem solved.
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
HVPS connection service check
Step
Questions / actions
Yes
No
1
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove shield. Is cable properly
connected to BCN1 on the HVPS and the
engine controller board HVCN connector?
Go to step 2.
Properly connect cable.
Retest printer. If error
clears, problem solved,
otherwise go to step 2.
2
Turn printer off, and remove items to expose
HVPS. See “High voltage power supply
(HVPS) removal” on page 4-40 for steps.
Check for continuity and pin shorts of cable
that connects engine controller board HVCN
and HVPS BCN1. Is cable okay? Also
ensure that there is no damage to the
connectors on both boards.
Replace HVPS. See “High
voltage power supply
(HVPS) removal” on
page 4-40. Retest printer. If
error clears, problem
solved, otherwise turn
printer off and replace
engine controller board.
See “Engine controller
board removal” on
page 4-34.
Replace cable. Retest
printer. If error clears,
problem solved, otherwise
turn printer off and replace
engine controller board.
See “Engine controller
board removal” on
page 4-34.
Diagnostic information
2-25
7100-XXX
Toner empty sensor (sender-TPD) service check
Step
Questions / actions
Yes
No
1
Turn printer off. and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Is cable properly connected to
engine controller board connector MCN8?
Go to step 2.
Properly connect cable.
Retest printer. If error
clears, problem solved,
otherwise go to step 2.
2
Check the following for continuity between
engine controller board MCN8 cable and
toner empty sensor (sender-TPD) cable.
See “Toner sensor (sender) removal” on
page 4-24 for steps to gain access to
sensor cable.
Go to step 3.
Replace cable. Retest
printer. If error clears,
problem solved, otherwise
go to step 3.
Toner empty sensor
MCN8
sender
pin 1
pin 1
pin 3
pin 2
pin 5
pin 3
Also check for shorted pins. Is cable okay?
3
Replace toner empty sensor (sender-TPD).
See “Toner sensor (sender) removal” on
page 4-24 for steps. Retest printer. Does
error clear?
Problem solved.
Go to step 4.
4
Replace engine controller board. See
“Engine controller board removal” on
page 4-34. POR printer. Does error clear?
Problem solved.
Contact higher level
support.
2-26 Service Manual
7100-XXX
Toner empty sensor (receiver-TTR) service check
Step
Questions / actions
Yes
No
1
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Is cable properly connected to
engine controller board connector MCN8?
Go to step 2.
Properly connect cable.
Retest printer. If error
clears, problem solved,
otherwise go to step 2.
2
Check the following for continuity between
engine controller board MCN8 cable and
toner empty sensor (receiver-TTR) cable.
See “Toner sensor (receiver) removal”
on page 4-43 for steps to gain access to
sensor cable.
Go to step 3.
Replace cable. Retest
printer. If error clears,
problem solved, otherwise
go to step 3.
Toner empty sensor sender
MCN8
pin 2
pin 1
pin 4
pin 2
pin 6
pin 3
pin 8
pin 4
pin 9
pin 5
pin 10
pin 6
Also check for shorted pins. Is cable okay?
3
Replace toner empty sensor (receiverTTR). See “Toner sensor (receiver)
removal” on page 4-43 for steps. Retest
printer. Does error clear?
Problem solved.
Go to step 4.
4
Replace engine controller board. See
“Engine controller board removal” on
page 4-34. POR printer. Does error clear?
Problem solved.
Contact higher level
support.
Diagnostic information
2-27
7100-XXX
Lower feed unit (secondary paper assembly) service check
Step
Questions / actions
1
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove shield. Is cable properly
connected to engine controller board
connector MCN6?
Go to step 2.
Properly connect cable.
Retest printer. If error
clears, problem solved,
otherwise go to step 2.
2
Remove right cover. See “Right cover
removal” on page 4-13. Check cable that
connects engine controller board connector
MCN6 to lower feed unit for continuity and
pin shorts. Is cable okay?
Go to step 3.
Replace cable.
3
Replace lower feed unit. See “Secondary
paper feed assembly removal” on
page 4-9. Does error clear?
Problem solved.
Go to step 4.
4
Replace engine controller board. See
“Engine controller board removal” on
page 4-34. Does error clear?
Problem solved.
Contact higher level
support.
2-28 Service Manual
Yes
No
7100-XXX
Tray empty service check
Step
Questions / actions
Yes
No
1
Remove paper tray from printer. Press
bottom of spring platform latches located in
rear corners of paper tray. This releases
spring platform of paper tray. Ensure tray is
raising paper after insertion. Is tray working
properly?
Go to step 2.
Replace paper tray.
2
Ensure paper empty sensor flag swings with
ease and is not broken or damaged. Is flag
working properly?
Go to step 3.
Replace paper guide (C)
assembly. See “Paper
guide C assembly
removal” on page 4-31.
3
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Is cable properly connected to
engine controller board connector MCN9?
Go to step 4.
Properly connect cable.
4
Reconnect operator panel. Turn printer on.
Touch negative lead of voltmeter to metal
frame to obtain ground. Touch positive lead
to engine controller board MCN9 pin 12 to
ensure 5 VDC is being supplied to paper
empty sensor. Is 5 VDC present?
Go to step 5.
Go to step 8.
5
insert empty paper tray into printer. Check
voltage level on MCN9 pin 14. Is 5 VDC
present?
Go to step 6.
Go to step 7.
6
Remove paper tray, fill with paper and
reinsert. Check voltage level on MCN9 pin
14. Is 0 VDC present?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Replace paper guide (C)
assembly. See “Paper
guide C assembly
removal” on page 4-31.
7
Turn printer off. Remove paper guide (C)
assembly. See “Paper guide C assembly
removal” on page 4-31. Check cable for
continuity that connects MCN9 pins 12, 13,
and 14 to paper empty sensor. Also check
for shorted pins. Is cable okay?
Replace paper guide (C)
assembly. See “Paper
guide C assembly
removal” on page 4-31.
Replace cable.
8
Check cable continuity between LVPS
ACN1 and engine controller board
connector POCN. Also check for shorted
pins. Is cable okay?
Replace LVPS. See “Low
voltage power supply
(LVPS) with cage
removal” on page 4-41.
Replace cable.
Diagnostic information
2-29
7100-XXX
Paper tray missing service check
Step
Questions / actions
1
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Is cable properly connected to
engine controller board connector MCN7?
Go to step 2.
Properly connect cable.
2
Turn printer on, and check for 5 VDC
between MCN7 pin 2 and ground. Is 5 VDC
present?
Go to step 4.
Go to step 3.
3
Check for cable continuity between LVPS
ACN1 and engine controller board POCN. Is
continuity present?
Replace LVPS. See “Low
voltage power supply
(LVPS) with cage
removal” on page 4-41.
Go to step 4.
4
With paper tray removed, take voltage
readings between ground and engine
controller board MCN7 pins 4, 6, 8 and 10.
Do you read 0 VDC on all the pins?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Go to step 5.
5
Check cable for continuity between engine
board MCN7 and paper size sensor. Also
check for shorted pins. Is cable okay?
Replace paper size sensor.
See “Left tray guide
assembly removal” on
page 4-43.
Replace cable by replacing
the left tray guide assembly.
See “Left tray guide
assembly removal” on
page 4-43.
2-30 Service Manual
Yes
No
7100-XXX
Toner low/empty service check
Step
Questions / actions
Yes
1
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Is cable properly connected to
engine controller board connector MCN8?
Go to step 2.
Properly connect cable.
2
Reconnect operator panel. Turn printer on.
Touch negative lead of voltmeter to metal
frame to obtain ground. Touch positive lead
to MCN8 pin 2, 4, 6, or 8 for specific color as
dictated by list below:
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Check cable for continuity
between engine controller
board connector MCN8 and
toner sensor system (both
sender and receiver). Also
check for shorted pins. See
“Toner sensor (sender)
removal” on page 4-24
and “Toner sensor
(receiver) removal” on
page 4-43 for steps to
expose cable. If cable is
okay, replace toner sensor
system.
Yes
No
MCN8
pin2–black(K)
pin4–yellow(Y)
pin6–magenta(M)
pin8–cyan(C)
Slightly remove toner cartridge in question.
Voltmeter should read approximately 4.8
VDC. Continue to slowly slide toner
cartridge out of printer while noting
voltmeter reading. Voltage should slowly
decrease until it reads approximately 0
VDC. Is toner sensor system working
properly?
No
Waste toner bottle service check
Step
Questions / actions
1
Remove waste toner bottle from printer.
inside waste toner bottle holder, check
sensor flag. Does flag work properly, and is
it not damaged?
Go to step 2.
Replace waste toner bottle
holder. See “Waste toner
bottle holder removal” on
page 4-22.
2
Reinstall waste toner bottle. Does error
clear?
Problem solved.
Go to step 3.
3
Replace waste toner bottle holder. See
“Waste toner bottle holder removal” on
page 4-22. Does error clear?
Problem solved.
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Diagnostic information
2-31
7100-XXX
Missing toner cartridge service check
Step
Questions / actions
1
Remove toner cartridge in question. Holding
toner cartridge with developer roller away
from you, check toner present sensor
actuators located on left rear of toner
cartridge. Are actuators damaged?
Replace toner cartridge.
Go to step 2.
2
Insert toner cartridge, and ensure toner
present sensor flag moves forward.
Remove toner cartridge. Toner present
sensor flag should spring forward. Does
toner present sensor flag operate correctly?
Go to step 3.
Replace toner present
sensor. See “Toner
present sensor removal”
on page 4-42.
3
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Is cable properly connected to
engine controller board connector MCN2?
Go to step 4.
Properly connect cable.
4
Reconnect operator panel. Turn printer on.
Touch negative lead of voltmeter to metal
frame to obtain ground. Touch positive lead
to engine controller board connector MCN2
pin 2 to ensure 5 VDC is being supplied to
toner present sensor. Is 5 VDC present?
Go to step 5.
Go to step 8.
5
Check voltage level on MCN2 pin 1. Is 5
VDC present?
Go to step 6.
Go to step 7.
6
install toner cartridge. Check voltage level
on MCN2 pin 1. Is 0 VDC present?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Replace toner present
sensor. See “Toner
present sensor removal”
on page 4-42.
7
Turn printer off. Check cable for continuity
that connects MCN2 pins 1, 2, and 3 to
toner present sensor. Also check for shorted
pins. Is cable okay?
Replace toner present
sensor. See “Toner
present sensor removal”
on page 4-42.
Replace cable.
8
Touch positive lead to engine controller
board connector POCN pins 13, 15, and 17
to ensure 5 VDC is being supplied to engine
controller board. Is 5 VDC present?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Go to step 9.
9
Check cable continuity between LVPS
ACN1 and engine controller board
connector POCN. Also check for shorted
pins. Is cable okay?
Replace LVPS. See “Low
voltage power supply
(LVPS) with cage
removal” on page 4-41.
Replace cable.
2-32 Service Manual
Yes
No
7100-XXX
Missing photodeveloper cartridge service check
Step
Questions / actions
Yes
No
1
Check photodeveloper cartridge for proper
installation. Is cartridge installed properly?
Go to step 2.
install properly.
2
Check printer contacts (A) and
photodeveloper cartridge contacts (B) for
dirt and damage. Are contacts okay?
Replace photodeveloper
cartridge. See
“Photodeveloper
cartridge removal” on
page 4-8.
Replace photodeveloper
cartridge. See
“Photodeveloper
cartridge removal” on
page 4-8.
Note: photodeveloper
cartridge is a customerordered supply.
If problem persists, replace
HVPS. See “High voltage
power supply (HVPS)
removal” on page 4-40.
A
B
Diagnostic information
2-33
7100-XXX
Transfer roller missing service check
Step
1
Questions / actions
Turn printer off, and check transfer roller
contacts. Are contacts present and not
damaged?
Yes
Go to step 2.
No
If contact A has slipped off
frame, put it back on. If you
cannot see it, remove
HVPS cage (see “HVPS
cage removal” on
page 4-42)and put it back
in place. If B is damaged,
replace registration
assembly. See
“Registration assembly
removal” on page 4-33.
A
B
2
Replace engine controller board. See
“Engine controller board removal” on
page 4-34. Does error clear?
2-34 Service Manual
Problem solved.
Replace HVPS. See “High
voltage power supply
(HVPS) removal” on
page 4-40.
7100-XXX
Cover open service check
Step
Questions / actions
1
Turn printer off, and remove right cover. See
“Right cover removal” on page 4-13.
Check all interlock switch (top, rear and
front) actuators for proper operation. Are
actuators good?
Yes
Go to step 2.
No
Replace appropriate
actuator:
Front cover for front cover
interlock switch. See
“Front cover assembly
removal” on page 4-12.
Top cover assembly for top
cover interlock switch. See
“Top cover assembly
removal” on page 4-10.
Rear cover actuator for rear
cover interlock switch.
Actuator is contained in
parts packet.
2
Check each interlock switch (top, rear and
front) for proper operation and damage.
Listen for switching action. Using an
ohmmeter, check switches. When switch is
open (cover open), resistance between pin
1 and pin 3 is 0 and pin 1 and 2 is infinite.
Closing switch will show 0 resistance
between pins 1 and 2 and infinite resistance
between pins 1 and 3. Are switches good?
Go to step 3.
Replace switch in question.
See “Front door interlock
switch with bracket” on
page 4-21 for front interlock
switch, see “Power supply
fan removal” on
page 4-49 for rear and top
interlock switches.
3
Turn printer on. Check for 5 VDC between
front cover interlock switch pin 1 (top pin)
and ground. Is 5 VDC present?
Go to step 5.
Go to step 4.
4
Turn printer off, and check cable for
continuity between LVPS ACN2 pin 1 and
cable that connects to front cover interlock
switch pin 1. Is cable okay?
Replace LVPS. See “Low
voltage power supply
(LVPS) with cage
removal” on page 4-41.
Replace cable.
5
Check the following cables for continuity:
Replace cable.
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
• Engine controller board MCN4 pin 1 to
rear interlock switch pin 3
• Engine controller board MCN4 pin 3 to
top interlock switch pin 3
• Top cover interlock switch pin 1 to front
cover interlock switch pin 2
• Top cover interlock switch pin 2 to rear
cover interlock switch pin 1
• LVPS ACN2 pin 2 to rear cover interlock
switch pin 2.
Are any cables defective?
Diagnostic information
2-35
7100-XXX
OPC belt (photodeveloper) cartridge drive service check
Step
Questions / actions
Yes
No
1
Check photodeveloper cartridge for proper
installation. Is cartridge installed properly?
Go to step 2.
install properly.
2
Check photodeveloper cartridge for
damage. Is cartridge damaged?
Replace photodeveloper
cartridge. See
“Photodeveloper
cartridge removal” on
page 4-8.
Go to step 3.
Note: photodeveloper
cartridge is a customerordered supply.
3
Check main motor assembly for damage. Is
main motor assembly damaged?
Replace main motor
assembly. See “Main
motor assembly removal”
on page 4-26.
Replace main drive
assembly. See “Main drive
gear assembly removal”
on page 4-27.
Yes
No
Missing fuser service check
Step
Questions / actions
1
Check photodeveloper cartridge for proper
installation. Is cartridge installed properly?
Go to step 2.
install properly.
2
Check photodeveloper cartridge for
damage. Is cartridge damaged?
Replace photodeveloper
cartridge. See
“Photodeveloper
cartridge removal” on
page 4-8.
Go to step 3.
Note: photodeveloper
cartridge is a customerordered supply.
3
Check main motor assembly for damage. Is
main motor assembly damaged?
2-36 Service Manual
Replace main motor
assembly. See “Main
motor assembly removal”
on page 4-26.
Replace main drive
assembly. See “Main drive
gear assembly removal”
on page 4-27.
7100-XXX
Paper size sensing service check
Step
Questions / actions
1
Turn printer off, and remove engine
controller board shield. See “Engine
controller board removal” on page 4-34
for steps to remove engine controller board
shield. Is cable properly connected to
engine controller board connector MCN7?
Go to step 2.
Properly connect cable.
2
Turn printer on, and check for 5 VDC
between MCN7 pin 2 and ground. Is 5 VDC
present?
Go to step 4.
Go to step 3.
3
Check for cable continuity between LVPS
ACN1 and engine controller board POCN. Is
continuity present?
Replace LVPS. See “Low
voltage power supply
(LVPS) with cage
removal” on page 4-41.
Go to step 4.
4
If paper tray is removed, set paper tray for
desired paper size, and insert paper tray
into printer. Using table below, check for
proper paper size sensor action by taking
voltage readings between ground and
engine controller board MCN7 pins 4, 6, 8
and 10. Is paper size sensor working
properly?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Go to step 5.
5
Check cable for continuity between engine
board MCN7 and paper size sensor. Also
check for shorted pins. Is cable okay?
Replace paper size sensor.
See “Left tray guide
assembly removal” on
page 4-43.
Replace cable by replacing
the left tray guide assembly.
See “Left tray guide
assembly removal” on
page 4-43.
Paper tray setting
Standard tray
Yes
No
MCN7 (all voltages measured from pin to ground)
pin 4
pin 6
pin 8
pin 10
A4
5 VDC
5 VDC
0 VDC
5 VDC
Letter
5 VDC
0 VDC
5 VDC
5 VDC
EXE
0 VDC
5 VDC
0 VDC
5 VDC
B5J
5 VDC
0 VDC
0 VDC
5 VDC
B51
5 VDC
0 VDC
0 VDC
5 VDC
#10
0 VDC
0 VDC
0 VDC
5 VDC
DL
0 VDC
0 VDC
0 VDC
5 VDC
Legal tray
0 VDC
0 VDC
5 VDC
5 VDC
Diagnostic information
2-37
7100-XXX
Printer no power service check
Note: If secondary paper feed assembly or duplex unit is installed, disconnect or remove before checking
base printer operation.
Step
Questions / actions
1
Reset printer, and listen for any activation of
motors and for power supply fan. Look at
operator panel to see if anything displays.
Do you hear sounds, or does the operator
panel display anything?
Go to step 2.
Go to step 3.
2
Disconnect and check continuity of power
cord. Is power cord good?
Go to step 3.
Replace power cord.
3
Ensure RIP board is properly installed. Is
RIP board installed correctly?
Go to step 4.
install RIP board.
4
Replace RIP board. See “System board
removal” on page 4-36. Does problem
persist?
Replace engine controller
board. See “Engine
controller board removal”
on page 4-34.
Problem solved.
5
Turn printer off, and check line voltage to
ensure that it is present and correct. Is
voltage present and correct?
Go to step 6.
inform customer.
6
Remove items (see “System board cage
removal” on page 4-39) from left side of
printer to expose power supply bracket.
Using an ohmmeter, ensure power switch is
good. Is power switch good?
Go to step 7.
Replace power supply
bracket. See “Low voltage
power supply (LVPS) with
cage removal” on
page 4-41 for steps to
remove power supply
bracket.
7
Check LVPS ACN1, ACN2, and ACN4 for
proper connection. Are cables properly
connected to LVPS?
Replace LVPS. See “Low
voltage power supply
(LVPS) with cage
removal” on page 4-41.
Properly connect cables.
2-38 Service Manual
Yes
No
7100-XXX
Toner feed service check
Step
Questions / actions
Yes
No
1
Check toner cartridge for damage. Check to
see if toner cartridge moves easily into and
out of printer. Is toner cartridge damaged or
is there resistance moving in and out of
printer?
Replace toner cartridge.
Go to step 2.
2
Is developer motor damaged?
Replace developer drive
assembly. See “Developer
drive assembly removal”
on page 4-22.
Go to step 3.
3
Is developer drive assembly damaged?
Replace developer drive
assembly. See “Developer
drive assembly removal”
on page 4-22.
Contact higher level
technical support.
Waste toner feed service check
Step
Questions / actions
Yes
No
1
Is transfer belt unit cleaning roller properly
installed?
Go to step 2.
Properly install cleaning
roller.
2
Check cleaning roller clutch gear (located
inside printer) for damage. Is cleaning roller
clutch damaged?
Replace cleaning roller
clutch.
Go to step 3.
3
Check waste toner bottle for overflow. Is
waste toner overflowing?
Go to “Waste toner bottle
service check” on
page 2-31.
Go to step 4.
4
Check waste toner auger for damage. Is
waste toner auger damaged?
Replace waste toner auger.
See “Waste toner auger
removal” on page 4-48.
Go to step 5.
5
Check waste toner agitator for damage. Is
waste toner agitator damaged?
Replace waste toner
agitator. See “Waste toner
agitator removal” on
page 4-48.
Go to step 6.
6
inspect waste toner feeder and opening in
bottom of printer. Is waste toner feeder
damaged?
Replace waste toner
feeder. See “Waste toner
feeder removal” on
page 4-28.
Problem solved.
Diagnostic information
2-39
7100-XXX
Operator panel service check
Step
Questions / actions
Yes
No
1
Is the operator panel cable properly
connected to the op panel?
Go to step 2.
Properly connect the cable
to the op panel.
2
Is the op panel cable properly connected to
the RIP board connector J-PNL1?
Go to step 3.
Properly connect the cable
to J-PNL1.
3
Check the op panel cable continuity. Is there
continuity?
Go to step 4.
Replace the flatbed unit.
See “Flatbed assembly
removal” on page 4-50.
4
Check Voltages on J-PNL1, located on the
RIP card. Pin 1 voltage should measure 5V.
Is it correct?
Replace the operator panel.
See “Operator panel
removal” on page 4-58.
Replace the system board.
See “System board
removal” on page 4-36.
Yes
No
USB service check
Step
Questions / actions
1
Is the USB cable properly connected to the
MFP and host PC?
Go to step 2.
Properly connect the cable
at both ends.
2
Try a different USB cable. Does this fix the
issue?
Issue fixed.
Go to step 3.
3
Connect a different device to the USB cable.
Did the host PC see the device?
Replace the RIP/system
board.See “System board
removal” on page 4-36.
There is an issue with the
host machine.
Network service check
Step
Questions / actions
1
Ping the MFP using the address on the MFP
op panel. Is it responding?
Go to step 3
Go to step 2.
2
Is the ethernet cable properly connected to
the network card RJ-45 connector?
Go to step 3.
Properly connect the cable
to the RJ-45 jack.
3
Check to see if DHCP is being used on the
network. Is DHCP used?
Go to step 4.
Go to step 5.
4
Does the MFP IP address match the ports
IP address on the driver?
Go to step 5.
Have the network admin
create a port on the host PC
matching the IP address on
the MFP. Assign the new
port to the driver.
5
Have the network admin try a new network
cable to the MFP. Did this fix the problem?
Problem resolved.
Replace the system board.
See “System board
removal” on page 4-36.
2-40 Service Manual
Yes
No
7100-XXX
Scanner / Copy / Fax service checks
Black page copy service check
Step
Questions / actions
Yes
No
1
Print a menu page, or a page from the host.
Is the page black?
See “High voltage power
supply (HVPS) service
check” on page 2-23
Go to step 2.
2
Is the CCD ribbon cable properly connected
to J-CCD on the system board?
Go to step 3.
Properly connect the ribbon
cable to J-CCD.
3
Check for +3.3VDC on pins 12 and 16 on
connector J-CCD. Pins 10 and 20 are
+5VDC. Pin 8 is +12VDC. Are the voltages
present?
Replace the flatbed unit.
See “Flatbed assembly
removal” on page 4-50.
Replace the system board.
See “System board
removal” on page 4-36.
Flatbed service check
Step
Questions / actions
Yes
No
1
Check to see if the flatbed is locked. Is it
locked?
Unlock the flatbed.
Go to step 2.
2
Ensure that the flatbed motor cable (JFB1)
is connected. Is the cable connected?
Go to step 3.
Properly connect the cable.
3
Check pin 1 in J-FB1 for voltage. The
voltage is only present when a copy job is
running. The voltage should measure 5V. Is
voltage present?
Replace the flatbed unit.
See “Flatbed assembly
removal” on page 4-50.
Replace the system board.
See “System board
removal” on page 4-36.
ADF streak service check
Step
1
Questions / actions
Do streaks appear on the middle of
scans when using the ADF?
Yes
Clean the ADF glass on the
flatbed using a lint-free cloth.
Also, clean the separator roll
and pad with a damp cloth.
No
No issue to fix.
Diagnostic information
2-41
7100-XXX
ADF paper feed service check
Step
Questions / actions
Yes
No
1
If the ADF is multi-feeding, check for dirt on
the ADF separator pad and ADF separator
rollers. Are they dirty?
Clean them with a lint free
cloth and isopropyl alcohol.
Replace the separator pad
and ADF pick roll.
2
If the paper is skewing when it is fed into the
ADF, check the paper guide width. Is it set
correctly?
Go to step 3.
Set the paper guides so
they contact the edges of
the paper.
3
If paper is skewing when fed or jamming
check to see if the top cover is open or ajar.
Is the ADF top cover open or ajar?
Properly close the top
cover.
If the paper is jamming in
the ADF, go to step 6
4
Is paper failing to feed into the ADF?
Go to step 5.
There is no issue.
5
Check the leading edge of the paper to
ensure the paper is not curled or bent in a
way that would keep it from contacting the
paper sensor actuator. Is the paper
damaged?
Bad media.
Go to step 6.
6
Is there dirt in the sensors, or is the paper
present actuator stuck?
Clean the sensors, or
remove debis from the
actuators.
Go to step 7.
7
Are the sensor actuators on the ADF
mechanism cover damaged?
Replace the ADF
mechanism cover.
Go to step 8.
8
Is the ADF connector properly connected to
J-ADF1 on the system board?
Go to step 9.
Properly connect the cable
to the system board.
9
inspect the connections on the ADF relay
card in the ADF. Are all the connections
properly connected?
Go to step 10.
Secure all the connections.
10
Check the ADF cable for continuity. Is there
continuity?
Go to step 11.
Replace the ADF cable.
11
Check for signals or voltages from J-ADF.
The voltage will only be present on pin 1
when a copy job is run. Pin one on
connector J-ADF1 should measure + 5v. Are
there signals or voltages present?
Replace the ADF unit. See
“ADF unit removal” on
page 4-54.
Replace the system board.
See “System board
removal” on page 4-36.
2-42 Service Manual
7100-XXX
Modem / fax card service check
Step
Questions / actions
Yes
No
1
Is the phone line properly connected to the
modem card and the wall jack?
Go to step 2.
Properly connect the phone
line to the modem card and
wall jack.
2
Is the modem card cable properly
connected to the system board at J-FAX-1
and the modem card?
Go to step 3.
Properly connect the
modem card cable to the
modem card and system
board.
3
Check the modem card cable for continuity.
Is there continuity?
Go to step 4.
Replace the modem card
cable.
4
Check the voltages from connector JFAX1on the RIP card. Check pins 1 and 2
for +3.3V. Pins 24, 27 and 28 are grounds.
Are there signals or voltages present?
Replace the modem card.
See “Modem card
removal” on page 4-46.
Replace the system board.
See “System board
removal” on page 4-36.
Diagnostic information
2-43
7100-XXX
Paper feed service checks
Printer paper feed service check
1
Problem area
Action
Check for recommended paper
Ensure paper being used is recommended.
Ensure paper is stored in an area free from high humidity.
Note: Disconnect secondary paper assembly, if installed, to help
isolate a paper transport problem.
2
Paper tray
Ensure paper tray is not damaged.
Check for paper caught behind tray in pickup transport roll.
Replace any damaged parts.
3
• Paper feed roller
• Separator pad
Check paper feed roller and separator pad for wear or damage. See
“Paper feed roller removal” on page 4-32.
Replace any damaged parts.
4
• Registration roller
• Transfer roller
Check registration roller for damage or binds, and replace if
necessary. See “Registration assembly removal” on page 4-33.
Check transfer roller for damage, and replace if necessary. See
“Transfer roller removal” on page 4-6.
5
Transfer belt unit
Ensure transfer unit is not damaged and is free of foreign material.
Note: Do not touch transfer belt with your hands.
6
Transfer belt unit cleaning roller
Ensure no paper is jammed in cleaning roller.
Ensure cleaning roller is not damaged.
Replace cleaning roller if necessary.
7
Fuser assembly
Ensure fuser assembly is not damaged or dirty.
Ensure fuser assembly guides and gears are not broken and are
free of paper.
Note: Fuser assembly is a customer-ordered supply.
8
• Paper exit assembly
• Gears
Check rear cover assembly for damage.
Ensure paper exit roller located in paper exit assembly is not
damaged.
Ensure paper exit gears and bearings are good.
Ensure paper guides are not bent or dirty.
Clean or replace parts if necessary.
2-44 Service Manual
7100-XXX
Print quality service checks
Background service check
Background is smeared due to toner spread.
Problem area
Action
1
Toner cartridge
Too small charging amount in the development process.
2
Check developer high voltage contact points.
insufficient contact of developer roller's primary or secondary
high voltage contact points. Ensure primary and secondary
contact points are free from contamination and toner debris.
Check toner cartridge developer roller bias pole. If
contaminated, clean it. If damaged or deformed, replace toner
cartridge.
3
Photodeveloper (OPC) cartridge
Photodeveloper cartridge has reached life or is failing.
Replace photodeveloper cartridge. See “Photodeveloper
cartridge removal” on page 4-8.
Note: Photodeveloper cartridge is a customer-ordered
supply.
4
High voltage power supply (HVPS)
HVPS has failed. Replace HVPS. See “High voltage power
supply (HVPS) removal” on page 4-40.
Diagnostic information
2-45
7100-XXX
Back stain service check
Backside of paper is stained.
Problem area
1
Fuser assembly
Action
• Fuser roller and back-up roller are stained.
• Fusing offset error occurred.
Replace fuser assembly. See “Fuser assembly removal” on
page 4-6.
Note: Fuser assembly is a customer-ordered supply.
2
Transfer roller
2-46 Service Manual
Transfer roller is stained. Replace transfer roller. See
“Transfer roller removal” on page 4-6.
7100-XXX
Banding service check
A banding line appears in horizontal direction.
1
Problem area
Action
Photodeveloper (OPC) cartridge
Transfer failure due to uneven rotational speed caused by a
shock which occurs when the seam of the OPC belt passes
over the cleaning blade.
Replace photodeveloper cartridge. See “Photodeveloper
cartridge removal” on page 4-8.
2
Toner cartridge
OPC belt and transfer belt fail to maintain regular and proper
rotation due to impact created during retract of toner cartridge.
Replace toner cartridge.
Diagnostic information
2-47
7100-XXX
Black line service check
A fine black line appears in printer image.
1
Problem area
Action
Toner cartridge
Toner cartridge blade is deformed.
Replace toner cartridge.
2
Photodeveloper (OPC) cartridge
OPC belt surface is damaged. Replace photodeveloper
cartridge. See “Photodeveloper cartridge removal” on
page 4-8.
3
Debris
Foreign particles (paper dust, and so on) have adhered to
perimeter parts of OPC belt and transfer unit belt. Clean
perimeter of mounting area of OPC belt and transfer belt.
2-48 Service Manual
7100-XXX
Color misregistration service check
Color misregistration between two colors.
1
Problem area
Action
Transfer roller and transfer belt cleaning roller
Transfer belt fails to maintain regular and proper rotation due
to impact caused when transfer roller or transfer belt cleaning
roller contacts transfer belt.
Ensure transfer roller and transfer belt cleaning roller are
properly installed.
2
Toner cartridge
Developer cartridge OPC belt fails to maintain regular and
proper rotation due to impact caused when toner cartridge
contacts OPC belt.
Ensure toner cartridge is properly installed.
3
Photodeveloper cartridge
OPC belt is off track.
Replace photodeveloper cartridge. See “Photodeveloper
cartridge removal” on page 4-8.
Note: Photodeveloper cartridge is a customer order supply.
4
Transfer belt unit
Transfer belt is off track.
Replace transfer belt unit. See “Transfer belt unit removal”
on page 4-5.
Diagnostic information
2-49
7100-XXX
insufficient fusing service check
Printed image is partially missing.
Problem area
Action
1
Fuser tension release lever
Fuser tension release lever is open. Check fuser, and remove
shipping pieces if still installed. Close release lever.
2
Driver media settings
Driver media setting is wrong. Ensure proper media setting is
selected for specific media in use.
3
Non-recommended paper
Non recommended paper is being used. Replace paper with
recommended paper.
4
Fuser
Replace failed fuser. See “Fuser assembly removal” on
page 4-6.
Note: The fuser is a customer order supply.
2-50 Service Manual
7100-XXX
insufficient gloss service check
Gloss on paper is not sufficient.
Problem area
Action
1
Driver media settings
Driver media setting is wrong. Ensure proper media setting is
selected for specific media in use.
2
Fuser
Fuser roller is deteriorated.
Fuser temperature is not properly controlled.
Replace fuser. See “Fuser assembly removal” on page 4-6.
Note: The fuser is a customer order supply.
Diagnostic information
2-51
7100-XXX
Jitter service check
Uneven optical density appears periodically in horizontal direction.
1
Problem area
Action
Photodeveloper cartridge
Replace faulty photodeveloper cartridge. See
“Photodeveloper cartridge removal” on page 4-8.
Note: Photodeveloper cartridge is a customer order supply.
2
Main motor assembly
• Irregular rotation of main motor assembly
• Main motor assembly gear unit failure
• Variation of OPC belt running speed due to failing main
motor assembly
Replace main motor assembly. See “Main motor assembly
removal” on page 4-26.
3
Developer drive assembly
Replace faulty developer drive assembly. See “Developer
drive assembly removal” on page 4-22.
2-52 Service Manual
7100-XXX
Missing image at edge service check
Image has missing or peeling toner at edge.
1
Problem area
Action
Toner cartridge
Too small a toner mass amount and charging amount in the
development process.
Replace toner cartridge.
2
Photodeveloper cartridge
OPC belt is deformed and wavy.
Replace photodeveloper cartridge. See “Photodeveloper
cartridge removal” on page 4-8.
Note: Photodeveloper cartridge is a customer order supply.
Diagnostic information
2-53
7100-XXX
Mixed color image service check
Mixed color image appears.
1
Problem area
Action
Toner cartridge
Ensure toner cartridge moves in and out of printer without a lot
of resistance. Compare toner cartridge in question with one of
the other known working cartridges.
Replace toner cartridge if defective.
2
Transfer roller clutch
Replace transfer roller clutch. See “Clutch removal” on
page 4-27.
3
Transfer belt unit cleaning roller clutch
Replace transfer belt unit cleaning roller clutch. See
“Cleaning roller clutch removal” on page 4-25.
2-54 Service Manual
7100-XXX
Mottle service check
Variation of optical density is found in image.
1
Problem area
Action
Rear cover assembly
Rear cover assembly is not fixed in place.
Open rear cover assembly, and close properly.
2
Transfer roller
Transfer roller is not properly installed.
Remove and reinstall transfer roller. See “Transfer roller
removal” on page 4-6.
3
Paper
Replace deformed paper.
4
Toner cartridge
Replace defective toner cartridge.
5
HVPS
Replace faulty HVPS. See “High voltage power supply
(HVPS) removal” on page 4-40.
Diagnostic information
2-55
7100-XXX
Residual image service check
Image of preceding page appears on every other page.
1
Problem area
Action
Transfer unit cleaning roller
Cleaning roller is not installed properly. Remove and reinstall.
Ensure left side of cleaning roller is making good contact with
HVPS contact.
If error continues to occur after reinstallation, replace cleaning
roller. See “Transfer belt cleaning roller removal” on
page 4-4.
2
HVPS
2-56 Service Manual
Replace faulty HVPS. See “High voltage power supply
(HVPS) removal” on page 4-40.
7100-XXX
Ribbing service check
Light print occurs in right or left side of image.
1
Problem area
Action
Printer is not level
Table printer is sitting on is slightly tilted.
Tilt should be less than 1/2 inch.
Confirm the printer table is large enough and the printer is
level.
2
Toner cartridge
insufficient amount of toner in the toner cartridge.
Shake the toner cartridge horizontally several times to level
the toner.
3
Toner cartridge
Toner in the toner cartridge is not level and collects on one
side.
Shake the toner cartridge horizontally several times to level
the toner. If problem persists, replace toner cartridge.
4
Rear cover assembly
Open rear cover assembly, and close properly.
5
Photodeveloper cartridge
Photodeveloper OPC belt is off rack and becomes deformed
during operation.
Replace photodeveloper cartridge. See “Photodeveloper
cartridge removal” on page 4-8.
Note: Photodeveloper cartridge is a customer order supply.
Diagnostic information
2-57
7100-XXX
Smear service check
The entire image appears smudged.
1
Problem area
Action
Photodeveloper cartridge (OPC belt) and
transfer belt
This print quality issue is usually accompanied by a paper
jam.
Remove the photodeveloper cartridge, and check for a
piece of paper on the rear side of the photodeveloper
cartridge. Remove the piece of paper from the
photodeveloper.
Note: This occurs mostly with A5 and B5 size
media.
2-58 Service Manual
7100-XXX
Toner drop service check
A toner spot stain on paper is caused by ambient toner within printer engine.
1
Problem area
Action
Waste toner feed system
Toner drops on the transfer drum due to a breakdown of the
waste toner feed system.
• Waste toner auger
• Waste toner feeder
2
Transfer unit cleaning roller
• Waste toner auger mylar is damaged. Examine and replace
if defective. See “Waste toner auger removal” on
page 4-48.
• Waste toner is not properly collected by waste toner feeder.
Check to ensure that waste toner feeder is not compacted.
If so, replace waste toner feeder. See “Waste toner feeder
removal” on page 4-28.
• Check for waste toner in printer. If found, clean and vacuum
printer.
Cleaning roller is faulty.
Remove transfer belt unit (see “Transfer belt unit removal”
on page 4-5). Replace cleaning roller. See “Transfer belt
cleaning roller removal” on page 4-4. Prior to installation of
new cleaning roller, thoroughly clean cleaning roller
installation area.
Check for waste toner in printer. If found, clean and vacuum
printer.
3
Toner cartridge
Replace faulty toner cartridge.
Diagnostic information
2-59
7100-XXX
Vertical line service check
A vertical line appears in printed image.
1
Problem area
Action
Photodeveloper cartridge (OPC belt) and
transfer belt
Foreign particles (dust and so on) adhere to parts located
around photodeveloper cartridge and transfer belt unit which
consequently contact toner image on transfer belt unit.
Remove and clean photodeveloper cartridge, transfer belt
unit, and adjacent areas.
2
Transfer unit cleaning roller and waste toner
auger
2-60 Service Manual
Cleaning roller and waste toner auger area are dirty.
Remove cleaning roller and clean waste toner auger and area
around it. Reinstall cleaning roller.
7100-XXX
Vertical staggering image service check
Printed image staggers in vertical direction.
Problem area
Action
1
Printer vibration
Check for printer vibrations or shock to printer.
2
Laser unit assembly (printhead)
Optical unit failure caused by vibration from scanner motor
rotation.
Replace laser unit assembly. See “Upper right rear cover
removal” on page 4-17.
Diagnostic information
2-61
7100-XXX
Vertical white band service check
White band appears in vertical direction of printed image.
Problem area
Action
1
Toner cartridge
Replace faulty toner cartridge.
2
Photodeveloper cartridge
Replace faulty photodeveloper cartridge. See
“Photodeveloper cartridge removal” on page 4-8.
3
Transfer belt unit
Replace faulty transfer belt unit. See “Transfer belt unit
removal” on page 4-5.
2-62 Service Manual
7100-XXX
White band service check
Horizontal white banding creates missing portion of image.
Problem area
1
Transfer roller
2
Transfer roller clutch
Action
• Transfer roller bias pole is not making proper contact with
high voltage spring contact. Remove and reinstall transfer
roller. Ensure spring contact on left side (looking from front
of printer) is not damaged.
• Replace faulty transfer roller. See “Transfer roller
removal” on page 4-6.
Replace faulty transfer roller clutch. See “Clutch removal”
on page 4-27.
Diagnostic information
2-63
7100-XXX
White line I service check
Vertical white line appears in a specific color area when print quality test print is run.
Problem area
Action
1
Test print
Print the maintenance page. See “Printing the maintenance
and configuration pages” on page 3-3. White line appears
on specific color.
2
Toner cartridge
• Developer roller of specific toner cartridge is dirty. Remove
foreign particle adhering to specific toner cartridge
developer roller.
• Developer roller surface is damaged. Replace problem
toner cartridge.
White line II service check
Vertical white line appears from leading edge to trailing edge of printed image.
1
Problem area
Action
Laser unit assembly (printhead)
Dust-proof glass of laser unit is smeared with toner or foreign
particles. Clean glass:
• Remove toner cartridges and photodeveloper cartridge.
See “Photodeveloper cartridge removal” on page 4-8.
• Open dust-proof glass cover.
• Clean glass.
There are foreign particles adhering to laser beam opening of
printhead. Clean laser beam opening.
2
Toner cartridge
2-64 Service Manual
Foreign particles mixed in toner cartridge. Replace faulty
cartridge.
7100-XXX
White spot / black spot service check
A white spot and black spot appear on paper.
1
Problem area
Action
Photodeveloper cartridge
There are foreign particles adhering to photodeveloper OPC
belt. Remove photodeveloper cartridge (see
“Photodeveloper cartridge removal” on page 4-8).
Lightly wipe off foreign particles using a cotton cloth.
If problem persists, replace photodeveloper cartridge.
2
Transfer belt unit
There are foreign particles adhering to transfer belt unit.
Remove transfer belt unit (see “Transfer belt unit removal”
on page 4-5).
Lightly wipe off foreign particles using a cotton cloth.
If problem persists, replace transfer belt unit.
3
Toner cartridge
Foreign particles mixed in toner. Replace toner cartridge.
4
Transfer roller
There are foreign particles adhering to transfer roller, or
transfer roller is deformed. Replace transfer roller. See
“Transfer roller removal” on page 4-6.
Diagnostic information
2-65
7100-XXX
White print service check
Blank page (no print at all) is printed or, a specific color is missing.
Problem area
Action
Solid white print
1
Optical Unit (Printhead)
Laser light path is blocked by paper or other material stuck at
the opening of the optical unit. Ensure there are no foreign
particles stuck at the opening of the optical unit.
2
Transfer roller
Transfer roller is not properly installed. Remove transfer roller
and reinstall. See “Transfer roller removal” on page 4-6.
Ensure transfer roller bias pole is touching spring contact on
left side (as viewed from front of printer) of roller.
3
HVPS
Replace faulty HVPS. See “High voltage power supply
(HVPS) removal” on page 4-40.
One color missing
4
Toner cartridge
2-66 Service Manual
Replace faulty toner cartridge.
7100-XXX
Wrinkle / image migration service check
Banding shadows of different optical density appear due to wrinkle, image migration, and color
misregistration occurring on paper.
Problem area
Action
1
Non-recommended paper
Paper being used is not recommended for printer. Replace
paper with recommended paper.
2
Rear cover assembly
Open rear cover assembly and reclose, ensuring that both
sides properly latch.
3
Fuser assembly
• Ensure fuser assembly is properly installed and that both
locking levers are locked. See “Fuser assembly removal”
on page 4-6.
• Replace faulty fuser assembly.
Note: Fuser assembly is a customer order supply.
Diagnostic information
2-67
7100-XXX
Uneven density (right and left)
Optical density is different between right and left side of printed image.
Problem area
Action
1
Rear cover assembly
Open rear cover assembly and reclose, ensuring that both
sides properly latch. If rear cover assembly will not properly
latch, ensure that white door actuators located at top of rear
cover assembly are not damaged. If damaged, replace. These
items are part of parts packet. If actuators are not damaged,
and door will still not latch, replace rear cover assembly. See
“Rear cover assembly removal” on page 4-14.
2
Transfer roller
Transfer roller is not properly installed. Remove transfer roller
and reinstall. See “Transfer roller removal” on page 4-6.
Ensure transfer roller bias pole is touching spring contact on
left side (as viewed from front of printer) of roller.
3
Laser unit assembly (printhead)
Dust-proof glass of laser unit is smeared with toner or foreign
particles. Clean glass:
• Remove toner cartridges and photodeveloper cartridge.
See “Photodeveloper cartridge removal” on page 4-8.
• Open glass cover.
• Clean glass.
There are foreign particles adhering to laser beam opening of
printhead. Clean laser beam opening.
4
Toner cartridge
Toner cartridge has insufficient amount of toner. Replace toner
cartridge.
5
Photodeveloper cartridge
Replace faulty photodeveloper cartridge. See
“Photodeveloper cartridge removal” on page 4-8.
6
Transfer belt unit
Replace faulty transfer belt unit. See “Transfer belt unit
removal” on page 4-5.
2-68 Service Manual
7100-XXX
Spacing table
Roller specifications
Name of roller
Diameter
(mm)
Number of rotations
(rpm)
Repeating defect on
print
(mm)
Registration assembly rubber roller
ø 14
283
43
Registration assembly steel roller
ø 12
321
38
Transfer roller
ø 20
194
63
Developer roller
ø 18
345
35
Transfer belt drive roller (part of transfer
belt unit)
ø 30
128
95
Transfer belt cleaning roller
ø 26
182
67
OPC belt charge brush (part of
photodeveloper charging system)
ø 11
256
47
OPC belt charge roller (part of
photodeveloper charging system)
ø 11
352
34.5
OPC belt drive gear shaft
ø5
256
47
OPC belt drive roller
ø 30
128
95
Fuser roller (part of fuser)
ø 41
95
128
Fuser belt (part of fuser)
ø 30
128
95
Paper exit roller (part of paper exit
assembly)
ø 16
246
50
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3. Diagnostic aids
This chapter explains the tests and procedures to identify MFP failures and to verify repairs have corrected
the problem.
Understanding the MFP operator panel
.
The use of the buttons and the layout of the operator panel is described in the following table.
Number
Button
Function
1
LCD Display
All modes - Displays messages and prompts during operation. Displays settings
when new settings are specified.
2
Alpha / Numeric
Keys
Enters numbers and letters in the setting menu.
Copy mode – Enter copy quantity.
Scan mode – Enter ASCII characters for a Push Scan profile search.
Fax mode – Enter a Fax number. Enter ASCII characters for Fax speed dial
searches.
3
Black Start
initiates a black and white scan job in Copy and Scan modes. initiates the Fax TX
in Fax mode.
4
Color Start
initiates a color scan in Copy and Scan modes. Non functional in Fax mode.
5
Stop / Clear
Cancels copy, scan, and fax jobs.
6
Menu Keys
Up / Down keys – These keys are used to scroll through selections.
can be used to clear an item, and
can be used to enter a space.
Return – Exits to an upper level of a menu.
Select – This key is used to select and confirm settings, or enter a submenu.
7
Copy LED
Switches the MFP to Copy mode.
8
Scan LED
Switches the MFP to Scan mode.
9
Fax LED
Switches the MFP to Fax mode.
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Number
Button
Function
10
Reduce / Enlarge
Copy mode - Reduce or enlarge the image data to a copy job.
Scan mode - Select the push scan document size.
11
Lighter / Darker
Copy mode - Adjust the copy exposure (5 levels available).
Scan mode - Adjust the push scan density (5 levels available).
Fax mode - Adjust the fax contrast (3 levels).
12
Image Quality
Copy mode - Select the desired copy quality (Text, Photo, Mixed).
Scan mode - Select Push scan resolution.
Fax mode - Select the Fax resolution (Standard, Fine, Photo).
13
Shift
Press to access the other 10 speed dial settings.
14
Speed Dial (One
touch dial)
Scan mode - One touch key for Push Scan with one shift key to switch to 20 sets.
Fax mode - One touch key for Fax with one shift key to switch to 20 sets.
15
Re dial Pause
Scan mode - Display the latest push scan profile.
Fax mode - Redial or pause a Fax job.
16
Hook
Fax mode - Hook
17
Directory
Scan mode - Search Push Scan profile by name for a Push Scan job.
Fax Mode - Search Fax phone numbers by name or speed dial code.
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Retrieving, printing and restoring the MFP settings
Printing the maintenance and configuration pages
Before replacing the engine controller board or the system / RIP board, print out the maintenance and
configuration pages. These page contain the MFP setting information that will need to be reset on the new
board.
Printing the maintenance page
1. in Ready mode, press
2. Press
. The MFP will enter the admin menus.
twice to scroll to the Reports menu.
3. Press
.
4. Press
once to scroll to the Maintenance Page item.
5. Press and hold
. The maintenance page will print out.
Printing the configuration page
1. in Ready mode, press
2. Press
. The MFP will enter the admin menus.
twice to scroll to the Reports menu.
3. Press
.
4. Press
XX times to scroll to Configuration Page.
5. Press and hold
. The configuration page will print out.
Setting the country code
The country code must be reset when the system/RIP board is replaced. The country code setting
determines which communication protocols, compression settings, and signal strength settings will be used
for a given country or region. Failure to reset the country code can render the fax functionality unusable.
To set the country code, perform the following steps:
1. in Ready mode, press
2. Use the
3. Press
or
to enter the MFP menus.
keys to scroll to the Administration menu.
to select the Administration menu.
4. Use the
or
keys to scroll to the Country menu.
5. Use the
or
keys to scroll to the desired country or region.
6. Press
to select and confirm the country or region.
Scanner calibration and registration
The X5xx scanner is self-calibrating. Scanner calibration occurs every time the MFP is started. in addition,
calibration is performed before a scan, copy or fax action is performed.
Top edge registration is performed when the MFP is powered on and before every scan, copy, or fax. Right
and left edge registrations are performed only when the MFP is started.
If the scanner fails to calibrate, 006 Service Call / Scanner Unit will be displayed. Should this error display,
see “Flatbed service check” on page 2-41.
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Maintenance mode
Maintenance mode contains information and settings that can be used in servicing the X5xx series MFPs.
The maintenance mode menu is entered by holding down the
key when performing a POR. The various
items in maintenance mode are accessed by using the
and
keys to navigate within a submenu to
each item, and pressing the
to select the item. Press the
key to move up a level.
WARNING: These settings should not be used without the supervision of your secondary support center.
Display info
The default menu displayed when in maintenance mode is the Display info menu. To select this menu
item, press the
key. The Display info menu item contains printer-specific information. The information in
this menu is described below. Press
to exit this menu.
Model Name
Model Name is the default menu item in the Display info submenu.This item displays the MFP model
name. The options are X500, and X502. This item cannot be changed. Press
to exit this item.
FW Version
The FW Version submenu displays three different firmware related items. While in the Display info menu,
use the
and
keys to navigate to FW Version and press the
key to enter the submenu. FW
Version menu items are accessed by using the
and
keys to navigate within the submenu to each
item.
CTL FW Ver
CTL FW Ver displays the system board firmware version. It cannot be changed in the menu. This is the
default menu item in the FW Version submenu. Press
to exit this item.
Fax FW Ver
The second item is Fax FW Ver which displays the fax firmware version. It cannot be changed in the menu.
Press
to exit this item.
MCTL FW Ver
The third item is MCTL FW Ver which displays the engine controller board firmware version. It cannot be
changed in the menu. Press
to exit this item.
Press
to go back up to the Display info menu.
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Counter
The Counter submenu displays various counters maintained by the MFP. These are permanent counts.
While in the Display info menu, use the
and
keys to navigate to Counter and press the
key to
enter the submenu. Counter menu items are accessed by using the
and
keys to navigate within
the submenu to each item.
Printer Counter - This submenu maintains the base print engine counters. Use the
and
navigate to each counter within the submenu. Press
to select the displayed item. Press
item.
1.
2.
3.
4.
5.
6.
keys to
to exit an
Total page – Total number of pages printed
Total Image – Number of images printed
Black Image – Number of black color planes printed
Magenta – Number of magenta color planes printed
Cyan – Number of cyan color planes printed
Yellow –Number of yellow color planes printed
Scanner Counter - This submenu item displays the number of various scans performed by the MFP. Use
the
and
keys to navigate to each counter within the submenu. Press
to select the displayed
item. Press
to exit an item.
1. Total Page – Total number of pages scanned
2. Total Image – Total number of images
3. Black Page – Total number of black and white scans
4. Color Page – Total number of color scans
5. ADF Used – Total number of scans from the ADF
Jam Counter - This menu shows the number of jams in various areas of the MFP. Use the
and
keys to navigate to each counter within the submenu. Press
to select the displayed item. Press
exit an item.
to
1. Total – Total number of jams
2. ADF – Total number of ADF jams
3. Prt Output Bin – Total number of jams in the fuser area
4. internal – Total number of jams in the paper path
5. Tray 1 – Total number of paper tray jams.
Press
again to exit the Counter menu.
Print Reports
Print Reports is the second top level menu item. From the top level of the Maintenance mode menu, use
the
and
keys to navigate to Print Reports. Press
to select the Print Reports item.
G3 Protocol Dump List - This is the only menu item in the Print Reports submenu. This setting converts
inbound fax data into ASCII data to aid in troubleshooting fax issues. Press
to select this item.
Press
twice to return to the top level of the Maintenance mode menu.
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Engine maintenance
This submenu shows the replacement status of the various maintenance items on the MFP. From the top
level of the Maintenance mode menu, use the
and
keys to navigate to Engine Maintenance.
Press
to select the Engine Maintenance item. Use the
and
keys to navigate to the individual
settings in the Engine Maintenance menu. Press
to select the currently displayed item.
Replace OPC Belt
Replace Fuser
Replace TR Belt
Replace PQ Kit
Replace PF1 Kit
Replace PF2 Kit
Replace ADF Kit
Waste Toner Pack Life Setting To change the status of any item, use the
Press
key to scroll to the desired setting and press the
key.
twice to return to the top level of the Maintenance mode menu.
Scan Maintenance
Mono Compression Setting - This item lets you change the scan compression settings. The options are
MH, MR, and MMR. MH is the default setting. This is the only item in the Scan Maintenance menu.
Fax Maintenance
Modem Settings
The three modem settings submenu items can be accessed using the
individual settings. When the desired modem setting is displayed, press
and
keys to navigate to the
to select the item.
RX Level -–This item allows you to adjust the RX level. The options are 16, 26, 33, and 43 dBm. XXX is
the default. This setting is automatically set when the MFP is initialized at setup. Do not change this setting
without second-level support supervision. If the setting needs to be adjusted use the
and
keys to
navigate to the setting level, and press
to select the new setting. Press
to exit.
TX Level – This item allows you to adjust the TX level. The options are 0 to 15 dBm. 15 dBm is the default.
This setting is automatically set when the MFP is initialized at setup. Do not change this setting without
second-level support supervision. If the setting needs to be adjusted, use the
and
keys to navigate
to the setting level, and press
to select the new setting. Press
to exit.
Cable Equalizer – This setting affect signal attenuation distance and the physical distance the fax can be
from a repeater. The options available for this setting are 0 km, 1.8 km, 3.6 km, and 7.2 km. Do not change
this setting. If the setting needs to be adjusted, use the
and
keys to navigate to the setting level,
and press
to select the new setting. Press
to exit.
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Protocol Definition
The two submenu items can be accessed using the
and
keys to navigate to the individual settings.
When the desired protocol definition setting is displayed, press
to select the item.
Training Retries – This is the number of attempts made to receive a fax before switching to a different
compression setting. When Training Retries is selected, use the
and
keys to navigate to the
desired number of retries, and press
to select the new setting. Press
to exit.
Encoding – This allows you set the fax compression setting. The options are JBIG, MMR, MR, and MH.
This can also be changed in the user menus. When Encoding is selected, use the
and
keys to
navigate to the desired encoding, and press
to select the new setting. Press
to exit.
Protocol Definition Timer – These settings affect the time duration before a protocol used to transmit a
fax is switched. This setting is country or region dependent and should not be changed without supervision
of a second-level support person.
T0 Timer
T1 Timer
T4 Timer
RX Settings
Silence Detection Time
CNG Tone Detection Time
CNG Cycles
Tone Sound Monitoring
Stop / Clear Key - This makes the key functional or non-functional.
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Density Tune Up
These settings adjust the density of the separate color planes for the copy, scan, and fax functions. These
settings should not be adjusted without second-level support center supervision.
The density tune-up menu items can be accessed using the
settings. When the desired modem setting is displayed, press
and
keys to navigate to the individual
to select the item.
Copy
The COPY settings submenu items can be accessed using the
and
keys to navigate to the
individual settings. When the desired modem setting is displayed, press
to select the item. Each
individual density setting can be adjusted by using the
and
to increment or decrement the density
value. When the desired value is displayed, press
to accept and set the value. Press
to exit the
submenu item.
Density Notch 1 (0-255) +127 is the default.
Density Notch 2 (0-255) +127 is the default.
Density Notch 3 (0-255) +127 is the default.
Density Notch 4 (0-255) +127 is the default.
Density Notch 5 (0-255) +127 is the default.
Scan
The SCAN settings submenu items can be accessed using the
and
keys to navigate to the
individual settings. When the desired setting is displayed, press
to select the item. Each individual
density setting can be adjusted by using the
and
to increment or decrement the density value.
When the desired value is displayed, press
to accept and set the value. Press
to exit the submenu
item.
Density Notch 1 (0-255) +127 is the default.
Density Notch 2 (0-255) +127 is the default.
Density Notch 3 (0-255) +127 is the default.
Density Notch 4 (0-255) +127 is the default.
Density Notch 5 (0-255) +127 is the default.
Fax
The FAX settings submenu items can be accessed using the
and
keys to navigate to the individual
settings. When the desired setting is displayed, press
to select the item. Each individual density setting
can be adjusted by using the
and
to increment or decrement the density value. When the desired
value is displayed, press
to accept and set the value. Press
to exit the submenu item.
Normal (0-255) +127 is the default.
Dark (0-255) +127 is the default.
Light (0-255) +127 is the default.
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Printer theory of operation
Electrophotographic Process (EP process)
The method that all laser and LED printers use to print is called the electrophotographic process. Laser
printers use differences in charge to manipulate and move toner from the toner cartridge to the printed
page.
Even though the basic EP Process is the same for every laser and LED printer, the specifics for each printer
are different. We will discuss the Lexmark X500n MFP and its particular method of printing.
EP Basics
The Lexmark X500n is a single laser MFP that uses four toner cartridges (Cyan, Yellow, Magenta and
Black) to create text and images on media. The MFP has one photodeveloper (called a photodeveloper
cartridge or OPC) and a transfer Unit. Each color toner is painted to the photodeveloper and to the transfer
unit one color or “image” at a time. The photodeveloper and transfer unit must rotate four times to print one
page composed of the four images for a color print job. During the printing process, the printer follows the
six basic EP process steps to create its output to the page.
These six steps are:
1. Charge the photodeveloper (OPC)
2. Expose the photodeveloper (OPC)
3. Develop toner on the photodeveloper (OPC)
4. 1st and 2nd transfer of toner to the transfer Unit and then to the media
5. Fuse toner to the media
6. Clean/Erase the photodeveloper and transfer Unit
in summary, the printer RIP board receives the command to print. The RIP board then sends a signal to the
engine controller board to start the print process. The engine controller board is the command center for the
EP process. The engine card coordinates the various clutches, motors and signals.
The high voltage power supply sends a charge to various components in the EP process. The laser fires on
the photodeveloper and creates an invisible image on the surface. One toner cartridge is pushed against
the photodeveloper for each rotation of the OPC, and toner is developed on the surface of the OPC. The
image is then transferred to the transfer unit and the photodeveloper is cleaned and electrically erased. This
process continues until all four colors have been transferred to the transfer unit.
Media is picked up from the tray and carried to the registration rollers where it stops and it is timed to enter
the EP process at just the right moment. Next, it is carried to the transfer roller where the image is
transferred from the Transfer Unit to the media.
The media is carried to the fuser rollers, where heat and pressure are applied to the page to permanently
bond the toner to the page. The fuser rollers push the media into the output bin. The transfer unit is cleaned,
and the process begins again for the next page.
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Summary of the EP process on the X500
This graphic illustrates the steps of the EP process on the X500
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X500 EP steps in detail
Step 1: Charge
During the charge step, voltage is sent from the high voltage power supply to the charge roller inside the
photodeveloper. The charge roller is part of the photodeveloper unit.
The charge roller puts a uniform negative charge over the entire surface of the photodeveloper to prepare it
for the laser beam. This is the charge process.
Look at callout 1 in the picture below. This is the location of the charge roller inside the photodeveloper. The
charge roller is the main component in step 1 of the EP process.
Note: If the surface of the charge roller is damaged (such as a nick or pit), it will cause the charge to be
uneven on the photodeveloper. This will cause a repeating mark on the printed page. Check the service
manual for the repeating marks table.
Note: If the charge roller is severely damaged, the surface of the photodeveloper will not be charged
properly and heavy amounts of toner will be deposited on the photodeveloper. This will cause the printed
page to be saturated with 100% of each color.
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Step 2: Expose
During the expose step, the laser fires a focused beam of light at the surface of the photodeveloper and
writes an invisible image called a latent image or electrostatic image. This is repeated for each color
printed. This is the expose process.
The laser beam actually discharges the surface only where the beam hits the photodeveloper. This creates
a difference in charge potential between the exposed area and the rest of the photodeveloper surface.
Look at callout 2 in the picture below. This is the where the laser beam hits the photodeveloper in Step 2 of
the EP process.
Note: The laser beam passes through a glass lens as it exits the laser unit. If this lens gets contaminated
with toner or other debris, it will cause vertical streaking of white/lightness on the page. Cleaning the lens
will solve the problem.
Note: Never touch the surface of the photodeveloper with your bare hand. The oil from your skin may
cause a charge differential on the surface, and toner will not stick properly. The result would be repeating
blotches of voids/light print on a page. Then the photodeveloper will have to be replaced.
Note: The surface of the photodeveloper is coated with an organic substance that makes it sensitive to
light. Be sure and cover the photodeveloper when you are working on the printer so you don’t “burn” it. If
exposed to light for too long, it will cause light/dark print quality problems and have to be replaced.
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Step 3: Develop
Once the laser exposes the photodeveloper, the high voltage power supply sends a charge to the developer
roller. The first toner cartridge engages the photodeveloper so it is in contact with the surface. Because of
the charge difference between the toner on the developer roller and the electrostatic image created by the
laser, the toner will cling to the OPC. The toner will only stick where the laser exposed the surface. This is
the develop process.
This process is best illustrated by comparing it to using glue to write on a can and then rolling it over glitter.
The glitter sticks to the glue but won’t stick to the rest of the can.
Each toner image is developed and transferred to the photodeveloper one color at a time. The toner image
on the photodeveloper needs to be transferred to the transfer unit before the next color can be developed.
Look at callout 3 in the picture below. This is where the developer rollers in the toner cartridges touch the
surface of the photodeveloper during Step 3 of the EP Process.
Note: If the developer roller is damaged, it will not contact the surface of the photodeveloper properly. The
result could be repeating marks, thin vertical voids or thin vertical lines of color on the printed page. Check
the surface of the developer for damage.
Note: Never touch the surface of the developer roller with your bare hand. The oil from your skin may
cause a charge differential on the surface, and toner will not stick properly. The result would be repeating
blotches of voids/light print on a page. Then the affected cartridge would need to be replaced.
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Step 4: Transfer
First transfer
After the first plane of color is developed on the photodeveloper, the high voltage power supply sends
voltage to the transfer unit so the image on the photodeveloper is transferred to the transfer unit. This takes
place by a direct surface-to-surface contact between the photodeveloper and the transfer unit. This is the
first transfer process.
The photodeveloper continues to rotate around and is cleaned and erased. Then, a new charge is put on
the surface. The laser exposes the photodeveloper, and the next color is developed and transferred to the
transfer unit. This process continues until all four planes of color have been transferred to the transfer unit.
Look at callout 4 in the picture below. This is the where the photodeveloper transfers the toner to the
transfer unit and the first transfer of the EP Process.
Note: Never touch the surface of the transfer unit with your bare hand. The oil from your skin will cause a
charge differential on the surface and toner will not stick properly. The result would be repeating blotches of
voids/light print on a page. The transfer unit would need to be replaced.
Note: Don’t use solvents or other cleaners to clean the transfer unit surface. No matter how careful you
are, the surface will be compromised causing scratches or a charge differential that will produce a void or
light blotch on the printed page. The transfer unit would need to be replaced.
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Second transfer
Once the last plane of color is transferred to the transfer unit from the photodeveloper, media is picked from
the paper tray and carried to the transfer roller. The transfer unit continues to rotate around and meets the
paper at the Transfer Roller area.
The high voltage power supply sends voltage to the transfer roller to create a positive charge. Once the
paper passes between the transfer roller and transfer unit, the negatively charged toner clings to the paper
and the entire image is transferred from the transfer unit. This is the 2nd transfer process.
Look at callout 4 in the picture below. This is the where the transfer unit transfers the toner to the media by
way of the transfer roller and Step 4b of the EP process.
Note: If the transfer roller has nicks, pits or flat spots on it, the surface doesn’t come into contact with the
media and transfer unit properly. This will cause voids or lights spots on the page or repeating voids/light
areas, because the toner can’t be fully transferred due to the charge difference in the areas of damage.
Note: If the transfer roller does not engage the transfer unit, or does not have voltage coming from the high
voltage power supply, the toner will not fully transfer from the transfer unit; the entire page will be very light
or blank. Any toner that does transfer will be due to a “contact” transfer instead of a “charge” transfer. Check
the transfer roller clutch and the high voltage power supply contacts to the transfer roller.
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Step 5: Fuse
Once the image has been fully transferred to the media, the transfer roller helps move the paper into the
fuser area.
The fuser applies heat and pressure to the page to melt the tiny toner particles and bond them permanently
to the media. The fuser moves the paper from the rollers and into the exit bin. This is the Fuse Process.
Look at callout 5 in the picture below. This is the where the Fuser bonds the toner permanently on the page.
Note: If the fuser rollers are damaged, they can cause toner to be pulled off the page or cause paper jams.
Note: Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an improper media
setting. Always check the paper type setting on the printer and driver before replacing the fuser. A common
mistake is to print on heavier media (such as card stock) with the paper type set to plain paper.
Note: When removing paper jams from the fuser, be sure to use the fuser release tabs to relieve the
pressure on the page. in addition, never pull unfused toner through the fuser if you can help it; try to back
the jammed page out of the fuser in the opposite direction it was traveling.
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Step 6: Clean/Erase
There are two main cleaning processes that take place during the EP Process. One process cleans the
photodeveloper and the other cleans the transfer unit.
Photodeveloper clean/erase
After each plane of color has been transferred to the transfer unit from the photodeveloper, a cleaning
blade scrapes the remaining toner from the surface of the photodeveloper while an erase lamp
discharges the remaining voltage. This is the clean/erase process.
The photodeveloper surface is prepared to begin the EP cycle once again. This cleaning/erasing cycle
happens after each plane of color is transferred to the transfer unit.
Look at callout 6 in the picture below. This is where the photodeveloper is cleaned and erased in the
photodeveloper phase of the clean/erase step of the EP process.
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Transfer unit cleaning
Once the toner image on the transfer unit has been transferred to the page, the transfer unit rotates
around and is cleaned by the cleaning roller. This cleaning happens after each page is printed.
A clutch engages a cam to lower the cleaning brush on the surface of the transfer unit and another
clutch rotates the brush. The high voltage power supply sends a charge to the cleaning brush so the
toner will want to stick to the cleaning brush instead of the transfer unit surface.
The waste toner is kicked into a containment area and moved by an auger system into the waste toner
bottle. This is the transfer unit clean process.
Look at callout 6 in the picture below. This is the where the transfer unit is cleaned by the cleaning
roller.
Note: If the cleaning roller is not positioned properly, it will not contact the transfer unit surface
correctly. This results in waste toner remaining on the transfer unit and will cause residual images or
“ghost” images. in other words, the remaining toner from one page will carry over to the next page as a
light “ghosted” image on the printed page.
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Printer Components
The following graphic illustrates all the EP and paper transport processes in the X500
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Paper path components
in order for an image to be printed, the media has to be moved from the paper tray to the printer and
eventually exit into the output area.
The most important component in this process is this media itself. Old, damaged or out-of-specification
media can and will cause feed and transport problems. If you encounter problems, you should always
check the media first. See “Media input types and weights” on page 1-8. In addition, it is always good
practice to check the printer and driver settings to see if the media being used matches the user’s settings
in the driver. It is not uncommon to find a user printing on card stock with the printer programmed to print on
a plain paper setting.
The printer feed and transport components can fail and cause paper jams or other feed and transport
problems. These components should be examined for damage or wear and replaced if necessary.
X500n specific information
The Lexmark X500n has a simple “C” shaped paper path (see the picture below). The tray 1 paper path is
shown in red, and the optional tray 2 path is shown in blue (Tray 2 is not shown).
Note: The tray 1 and tray 2 paper paths merge at the tray 1 paperfeed roll.
Paper is fed from the rear of the printer and travels upward through the rear cover.
There is no duplex option or finisher option on this printer. There is a 530-sheet drawer available (not
shown).
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7100-XXX
Transport Components
In summary, as shown in the previous illustration, the media is fed from the paper tray into the printer by a
feed roller which carries the media to the registration rollers. The media trips the registration sensor. At this
point, the media pauses so the registration rollers can properly time the media entry to the EP process. The
registration rollers help ensure that the image is properly spaced and aligned on the media.
The registration rollers push the media to the transfer roller where the image is transferred to the page.
The transfer roller moves the media to the fuser. The fuser applies heat and pressure to the page. The heat
and pressure permanently bond the image to the media. The fuser rollers push the media toward the exit
bin and past the fuser exit sensor. The exit rollers guide the paper into the output bin.
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Paper jam messages
The following illustration lists paper jam messages indicating where the paper jam occurred.
CAUTION
When clearing paper jams, inside of the printer may be hot. Allow printer to cool
before touching any internal components.
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Accessing jam areas
Open doors and covers, and remove trays to access jam areas. The illustration shows the location of
sources and possible jam areas.
Use the following table to locate instructions for a particular jam; however, to resolve any message, you
must clear all media from the media path.
Jam message
Go to page
Paper Jam A1, Rear (tray 1)
“Paper Jam A1, rear (tray 1)” on
page 3-24.
Paper Jam A2, Rear (tray 2)
“Paper Jam A2, rear (tray 2)” on
page 3-26.
Paper Jam B, Rear
“Paper Jam B rear” on page 3-27.
Paper Jam C, Rear
“Paper Jam C rear” on page 3-29.
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Paper Jam A1, rear (tray 1)
A PAPER JAM-A1 message indicates the media is jammed in tray 1. To clear a jam from the standard tray
(Tray 1):
1. Pull the tray out. Remove the tray completely.
• For a misfeed of the media, the single piece of media is laying on top of the stack. Pull it straight out.
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• For media jammed behind the tray area, locate the jam on the bottom surface of the tray housing.
You may have to reach far under the printer to locate the jam, as shown in the following illustration.
Pull the jam straight out.
2. insert the tray.
3. If clearing paper doesn’t resolve the problem, see “Paper feed service checks” on page 2-44.
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Paper Jam A2, rear (tray 2)
A PAPER JAM-A2 message indicates the media is jammed in tray 2. To clear a jam from the optional 530sheet tray (Tray 2):
1. Pull the tray out. Remove the tray completely.
• For a misfeed of the media, the single piece of media is laying on top of the stack. Pull it straight out.
• For media jammed behind the tray area, locate the jam on the bottom surface of the support unit.
You may have to reach far under the printer to locate the jam. Pull the jam straight out.
2. Push the tray into the support unit.
3. If clearing paper doesn’t resolve the problem, replace the secondary paper feed assembly. See
“Secondary paper feed assembly removal” on page 4-9.
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Paper Jam B rear
CAUTION
When clearing paper jams, inside of the printer may be hot. Allow printer to cool
before touching any internal components.
A PAPER JAM-B message indicates the media is jammed behind the rear door. To clear this type of jam, do
the following:
1. Push the rear door release latch.
2. Gently lower the rear door.
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3. Pull the fuser pressure release levers to release tension on the media.
4. Grasp each side of the jammed media. Pull it to the rear of the printer and then out.
Note: Gently pull the media out so you do not tear it.
Note: If there is no media present in the fuser area, and print jobs appear smudged, see “Smear service
check” on page 2-58.
5. Close the rear door.
6. Check registration sensor and its actuator. Replace if damaged. See “Paper guide C assembly
removal” on page 4-31.
7. Ensure connector MCN9 on the engine controller board is connected. If connector is attached and error
persists, replace the engine controller board. See “Engine controller board removal” on page 4-34.
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Paper Jam C rear
A PAPER JAM-C message indicates the media is jammed behind the rear door above the fuser.
1. Push the rear door release latch, and gently lower the rear door.
2. Pull the fuser pressure release levers to release tension on the media.
3. Grasp each corner of the jammed media, and pull it up and out.
Note: Gently pull the media out so you do not tear it. Whenever possible, pull the media towards the
bottom of the printer to avoid contamination of the fuser.
4. Close the rear door.
5. Check fuser exit sensor (located in the paper exit assembly) and its actuator. Replace if damaged. See
“Paper exit assembly removal” on page 4-32.
6. Ensure connector MCN1 on the engine controller board is connected. If the connector is attached and
the error persists, replace the engine controller board. See “Engine controller board removal” on
page 4-34.
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ADF paper jams
An ADF JAM: Open ADF Cover and Clear Jam message indicates a jam in the ADF.
WARNING: Do not clear any ADF jams until the release lever on the ADF pick roller assembly is opened.
WARNING: Do not lift the flatbed lid and pull the jammed paper from the bottom of the ADF.
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To clear an ADF paper jam, follow these steps.
1. Open the ADF top cover.
2. Lift the green separator roll release lever to the up position. Do not remove the separator roll.
3. Pull the paper from the ADF assembly. Pull the paper in the direction of the ADF paper tray.
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4. Lower the separator roller release lever until it locks in place.
5. Close the ADF cover, and test the ADF.
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4. Repair information
Removal and cleaning precautions
Observe the following precautions whenever you service the MFP:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Prior to starting any repair, read and understand the warnings in this manual.
Be sure to unplug the MFP from the outlet before attempting to service the MFP.
To reassemble the MFP, reverse the order of removal unless otherwise specified.
Do not operate the MFP anytime during removals. If it is absolutely necessary to run the MFP with its
covers removed, use care not to allow your clothing to be caught in revolving parts such as the gears,
rollers and fan motor.
Never touch the terminals of electrical parts or high-voltage parts such as the high voltage power
supply.
Remove the ground wire when removing or replacing the low voltage power supply. After installation is
complete, confirm the ground wire is reconnected to the earth mark
.
After part replacement, ensure the wiring harness is not caught or damaged.
Do not attempt to cut or extend the wiring harness.
Confirm the wiring harness connector is connected properly.
Be sure to handle the fuser carefully, as it remains hot for a while after the MFP stops running. Always
unplug connectors by holding the connector housing.
Remember to install the ground wire or ground plate to ensure a positive conduction. Install the screw
with a toothed washer in the correct position at reassembly.
Never lift the MFP from the scanner assembly.
Confirm the direction of all parts and screw lengths during removal/replacement.
Any part where the mounting screws are used to meet a machine alignment set at the factory must not
be removed, disassembled, or adjusted. For example, the paper pickup roll mounting bracket or
internal parts not provided as replacement parts.
Utilize the proper cleaning procedures/solvents during maintenance.
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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 cards:
•
•
•
•
•
•
•
•
•
Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until you are ready to
install the part into the MFP.
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 MFP.
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 MFP 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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Photodeveloper cartridge
The following precautions must be observed when handling the photodeveloper cartridge or commonly
called OPC (optical photo conductor). The photodeveloper cartridge is a supply item you will have to
remove during some of the repair procedures:
During transportation/storage
Use the specified carton whenever moving or storing the photodeveloper cartridge.
Handling
• The OPC belt in the photodeveloper cartridge exhibits the greatest light fatigue after being exposed to
•
•
strong light over an extended period of time. Never expose it to direct sunlight. Cover the
photodeveloper cartridge when you remove it from the MFP.
Use care not to contaminate the surface of the OPC belt with oil-base solvent, fingerprints, and other
foreign matter.
Do not scratch the surface of the OPC belt.
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MFP removals
There are FRU/CRUs and supply items that will need to be removed prior to some of the removal
procedures. The removal procedure will specify when the part must be removed.
Cleaning roller cover removal
1. Raise the scanner unit.
2. Open the top cover.
3. Depress the tabs, and remove the cleaning roller cover.
Transfer belt cleaning roller removal
1. Remove the cleaning roller cover. See “Cleaning roller cover removal” on page 4-4.
2. Lift and remove the transfer belt cleaning roller.
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Transfer belt unit removal
1. Open the rear cover assembly.
2. Rotate the two captive screws (A) counterclockwise until they are loose.
A
Warning: Take great care when removing the transfer belt unit to prevent scratching the transfer belt. Do
not touch or hit the belt during removal.
3. Pull the transfer belt unit toward rear of the MFP, lift and remove.
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Transfer roller removal
1. Open the rear cover assembly.
2. Rotate the transfer roller to release; lift and remove.
Fuser assembly removal
1. Push the rear cover assembly latch, and lower the rear cover assembly.
2. Turn two green fuser release levers (A).
A
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3. Lift the fuser straight up and away from the MFP.
Waste toner bottle removal
1. Open the front cover.
2. Remove the waste toner bottle.
Warning: Ensure that the waste toner bottle is secured and not allowed to tip over during repair process.
Failure to adhere to this warning may result in toner spillage.
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Photodeveloper cartridge removal
Warning: Follow precautionary procedures (see “Photodeveloper cartridge” on page 4-3) when
removing the photodeveloper cartridge.
1.
2.
3.
4.
Raise the scanner assembly.
Open the top cover assembly.
Depress the release levers (A).
Lift and remove the photodeveloper cartridge.
5. Lay the photodeveloper cartridge as shown in a clean area.
6. Cover the photodeveloper cartridge with a piece of paper as shown.
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Secondary paper feed assembly removal
1. Remove the left secondary paper feed assembly cover. Repeat for the right side.
2. Loosen the thumbscrew (A) on the left bracket, and remove the bracket. Repeat for the right side.
3. With help from another person, lift the MFP by the recessed handholds and remove the MFP from the
secondary paper feed assembly.
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Cover removals
Top cover assembly removal
1.
2.
3.
4.
5.
6.
Remove the scanner assembly. See “Flatbed assembly removal” on page 4-50.
Remove the upper right rear cover. See “Upper right rear cover removal” on page 4-17.
Remove the cleaning roller cover. See “Cleaning roller cover removal” on page 4-4.
Remove the photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-8.
Open the OPC cover.
Remove the two screws (A) from the top cover assembly.
A
7.
8.
Open the rear cover.
Remove the upper right rear cover. See “Upper right rear cover removal” on page 4-17.
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9.
Remove the screw (B) which secures the top cover to the MFP frame.
B
10. Remove the upper left rear cover. See “Upper left rear cover removal” on page 4-17.
11. Remove the screw (C) which secures the top cover to the MFP frame.
C
12. Release the tabs on the front of the top cover assembly.
13. Lift the top cover assembly and remove.
Note: If you are replacing the top cover assembly, remove the scanner arms. They will be used on the new
top cover. See “Scanner arm removal” on page 4-53.
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Front cover assembly removal
1. Open the front cover assembly.
2. Remove the 8 screws (A) from the inner front cover.
3. Disengage the support strap from the MFP.
4. Release the tabs on the front cover.
5. Remove the front cover from the inner front cover.
6. Raise the inner front cover.
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7. Rotate the support pin away from the MFP, and slide toward the center of the MFP to remove. Repeat
for the other support pin
8. Remove the front inner cover from the MFP.
Right cover removal
1. Remove the waste toner bottle. See “Waste toner bottle removal” on page 4-7.
2. Remove the top cover assembly. See “Top cover assembly removal” on page 4-10.
3. Remove 2 screws (A) from the bottom of the right cover.
4. Remove the right cover from the MFP. Maneuver the front cover for easy removal.
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Rear cover assembly removal
1.
2.
3.
4.
5.
6.
Remove the fuser assembly. See “Fuser assembly removal” on page 4-6.
Remove the transfer belt unit. See “Transfer belt unit removal” on page 4-5.
Remove the right cover. See “Right cover removal” on page 4-13.
Disconnect the rear cover assembly connector (A).
Remove the support pin (B), disconnecting the support cable from the MFP.
Remove two screws (C) from the rear cover assembly.
A
B
C
7. Slide the right side of the rear cover assembly away from the MFP until the hinge clears the slot.
1
2
8. Slide the rear cover assembly toward the right side until the captured end of the rear cover assembly
clears the mounting bracket.
9. Remove the rear cover assembly by pulling it away from the MFP.
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Left front cover removal
1. Remove the top cover assembly. See “Top cover assembly removal” on page 4-10.
2. Remove two screws (A) from the bottom of the left front cover.
3. Remove the left cover from the MFP.
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Left rear cover removal
1. Remove the screw (A) that secures the left rear cover to frame.
A
2. Slide the left rear cover back, and remove it from the printer.
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Upper right rear cover removal
1. Open the rear cover. See “Rear cover assembly removal” on page 4-14.
2. Remove the screw (A) that secures the upper right rear cover to the frame.
A
3. Remove the upper right rear cover.
Upper left rear cover removal
1. Remove the left rear cover. See “Rear cover assembly removal” on page 4-14.
2. Remove the screw (A) that secures the upper left rear cover to the frame.
A
3. Remove the upper left rear cover.
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Laser unit assembly (printhead) removal
1.
2.
3.
4.
5.
Open the front cover.
Remove the toner cartridges.
Remove the photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-8.
Open the top cover assembly.
Remove the two screws (A) from the laser unit assembly cover. The photograph below is looking
through the opening in the top cover assembly.
A
6. Unlatch and remove the laser unit assembly cover.
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7. Remove four screws (B) from the laser unit assembly.
B
B
8. Remove the laser unit assembly from the MFP.
9. Disconnect the connector from the laser unit assembly.
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Erase lamp removal
1.
2.
3.
4.
Remove all the toner cartridges.
Remove the photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-8.
Remove the transfer belt unit. See “Transfer belt unit removal” on page 4-5.
Remove the two screws (A).
A
5. Disconnect the erase lamp cable (B).
6. Remove the erase lamp.
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B
A
7100-XXX
Right side removals
Front door interlock switch with bracket
1. Remove the top cover assembly. See “Top cover assembly removal” on page 4-10.
2. Remove the right cover. See “Right cover removal” on page 4-13.
3. Disconnect the interlock switch cable (A) from the interlock switch.
A
B
4. Remove the screw (B) and disengage the locking clip on the back of the bracket.
5. Remove the switch with the bracket.
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Waste toner bottle holder removal
1. Remove the right cover. See “Right cover removal” on page 4-13.
2. Disconnect the waste toner bottle holder connector (A).
A
B
3. Remove three screws (B) from the waste toner bottle holder. The bottom screw is longer than the other
screws.
4. Remove the waste toner bottle holder from the MFP.
Developer drive assembly removal
1. Remove the main motor assembly. See “Main motor assembly removal” on page 4-26.
2. Remove the waste toner bottle holder. See “Waste toner bottle holder removal” on page 4-22.
3. Remove four clips and the developer drive gears (A) from the inside of the MFP.
A
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4. Disconnect the developer driver assembly cables (B).
B
C
5. Remove the four screws (C) from the developer drive assembly.
6. Remove the developer drive assembly from the MFP.
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Toner sensor (sender) removal
1. Remove the developer drive assembly. See “Developer drive assembly removal” on page 4-22.
2. Remove two screws (A) from the toner sensor.
Note: The bottom screw is longer than the top screw.
A
3. Pull the toner sensor away from the MFP, disconnect the cable, and remove the sensor.
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Cleaning roller clutch removal
1. Remove the transfer belt cleaning roller. See “Transfer belt cleaning roller removal” on page 4-4.
2. Remove the right cover. See “Right cover removal” on page 4-13.
3. Using a flat-tipped tool, pry and remove the cleaning roller clutch gear from the inside of the MFP.
4. Disconnect the cleaning roller clutch cable (A).
5. Remove three screws (B) from the cleaning roller clutch.
A
B
6. Remove the cleaning roller clutch from the MFP.
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Main motor assembly removal
1. Remove the right cover. See “Right cover removal” on page 4-13.
2. Disconnect the main motor assembly cable (A) from the main motor.
3. Remove 4 screws (B) from the main motor assembly.
B
A
4. Remove the main motor assembly from the MFP.
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Clutch removal
Note: This procedure applies to the transfer roller clutch, registration clutch, and the paper feed clutch. The
transfer clutch removal is shown. This removal is typical for the others.
1. Remove the right cover. See “Right cover removal” on page 4-13.
2. Disconnect the clutch cable (A).
3. Remove the clip (B) from the clutch.
B
A
4. Slide the clutch away from the MFP to remove.
Main drive gear assembly removal
1. Remove the cleaning roller clutch. See “Toner sensor (sender) removal” on page 4-24.
2. Remove the main motor assembly. See “Main motor assembly removal” on page 4-26.
Note: If you are removing the main drive gear assembly to get to the waste toner feeder, you do not have
to remove the fuser, transfer roller, registration, or paper feed clutch. The clutches are removed at the
beginning of this procedure, because the main drive gear assembly FRU does not include the clutches.
3. Remove the transfer roller clutch. See “Clutch removal” on page 4-27.
4. Remove the registration clutch. See “Clutch removal” on page 4-27.
5. Remove the paper feed clutch. See “Clutch removal” on page 4-27.
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7100-XXX
6. Remove five screws (A) that secure the main drive gear assembly to the MFP.
B
A
Note: screw
shown removed.
7. Remove two screws (B) that secure the lower right frame.
8. Remove the main drive gear assembly from the MFP.
Note: When reinserting the main drive gear assembly, ensure that the bottom right corner is installed
before the lower right frame.
Waste toner feeder removal
1. Remove the main drive gear assembly. See “Main drive gear assembly removal” on page 4-27.
2. Loosen the two screws (A) of the sensor base to allow free movement of the waste toner feeder.
A
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3. Remove screw (B) from the waste toner feeder pipe.
B
4. Remove the waste toner feeder pipe from the waste toner bottle holder.
5. Pull and remove the waste toner feeder from the MFP.
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Rear removals
Bracket assembly removal
1.
2.
3.
4.
Remove the erase lamp. See “Erase lamp removal” on page 4-20.
Remove two screws (A).
Disconnect connector (B) from the transfer belt marker sensor.
Disconnect connector (C) from the toner density sensor.
5. Lift and remove the bracket assembly.
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Paper guide assembly removal
1. Remove the registration assembly. See “Registration assembly removal” on page 4-33.
2. Remove two screws (A) that attach the paper guide assembly to the MFP. Screws are located in holes.
3. Lift and remove the paper guide assembly (B) from the MFP.
B
Paper guide C assembly removal
1.
2.
3.
4.
Remove the paper guide assembly. See “Paper guide assembly removal” on page 4-31.
Remove the transfer belt unit. See “Transfer belt unit removal” on page 4-5.
Remove the support pin, disconnecting the support cable (A) from the MFP.
Remove the two screws (B) that attach the paper guide C assembly to the MFP.
5. Disconnect two sensor cables from the sensors located on the paper guide C assembly, and remove
the paper guide C assembly.
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Paper feed roller removal
1. Remove the paper guide C assembly. See “Paper guide C assembly removal” on page 4-31.
2. Slide the paper feed roller off the shaft to remove.
Paper exit assembly removal
1. Remove two screws (A).
A
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2. Disconnect the cable (B).
3. Remove two screws (C).
C
B
Registration assembly removal
1. Remove the transfer roller. See “Transfer roller removal” on page 4-6.
2. Remove three metal screws (A) and three plastic screws (B).
3. Lift and remove the registration assembly.
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Left side removals
Engine controller board removal
Warning: Before replacing the engine controller board, save the onboard settings. See “Printing the
maintenance and configuration pages” on page 3-3.
1. Remove the left front cover. See “Left front cover removal” on page 4-15.
2. Remove the system board. See “System board removal” on page 4-36.
3. Remove three screws (A) from the engine controller board shield; remove the shield.
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4. Disconnect all the connectors from the engine controller board.
5. Remove five screws (B) from the engine controller board; remove the engine controller board.
B
Note: When reinstalling flat cables, ensure that the blue side of the cable is opposite of the pins on the
connectors. Flat cable pins are exposed on only one side (opposite blue side) and must make contact with
the metal pins on the connectors.
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System board removal
CAUTION
There is a lithium battery on your system board. RISK OF EXPLOSION IF REPLACED BY
AN INCORRECT TYPE. The battery is non-replaceable. Do not replace, recharge,
disassemble, or incinerate a lithium battery. Discard used batteries according to the country,
state or local regulations.
Warning: Before replacing the system board, save the onboard settings. See “Printing the maintenance
and configuration pages” on page 3-3.
Warning: When replacing the System/RIP board, be sure to set the country code. See “Setting the
country code” on page 3-3.
1. Disconnect any attached USB or network cables.
2. Remove the left rear cover. See “Left rear cover removal” on page 4-16.
3. Remove the screw (A) securing the system board cover.
A
4. Remove the system board cage cover.
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5. Remove the screw (B) securing the two ground wires.
B
6. Disconnect all the cables from the system board.
7. Remove the four screws (C) securing the system board to the system board cage.
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8. Remove two screws (D) securing the system board to the system board cage.
9. Slide the system board out of the MFP.
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System board cage removal
1.
2.
3.
4.
5.
6.
Remove the left front cover. See “Left front cover removal” on page 4-15.
Remove the three screws (A) securing the engine card shield.
Remove the engine card shield.
Disconnect all the cables from the engine card.
Disconnect the modem speaker cable from the RIP card.
Remove the three screws (B) which secure the card cage to the printer frame.
7. Carefully remove the card cage from the printer.
Note: The engine controller board and system / RIP board do not need to be removed to perform this
removal.
Repair information
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High voltage power supply (HVPS) removal
1.Remove the RIP board cage. See “System board cage removal” on page 4-39.
2.Disconnect all the connectors from the HVPS.
Note: When reinstalling flat cables, ensure that the blue side of the cable is opposite of the pins on the
connectors. Flat cable pins are exposed on only one side (opposite blue side) and must make contact with
the metal pins on the connectors.
3. Remove 11 screws (A) (4 corner screws are gold in color (metal); inner screws are silver (plastic));
remove HVPS.
A
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Low voltage power supply (LVPS) with cage removal
1. Remove the transfer belt unit. See “Transfer belt unit removal” on page 4-5.
2. Remove the RIP board cage. See “System board cage removal” on page 4-39.
3. Remove the grounding terminal screw (A).
4. Disconnect the power supply bracket connector (B).
5. Remove three screws (C) that attach the power supply bracket; remove the power supply bracket.
C D
B
A
C
6. Remove the screw (D), and disconnect all the connectors from the LVPS.
7. Remove three metal screws (E) and 3 plastic screws (F) that attach the LVPS with the cage; remove
the LVPS with the cage.
F
E
F
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7100-XXX
HVPS cage removal
1. Remove the HVPS. See “High voltage power supply (HVPS) removal” on page 4-40.
2. Remove the LVPS with cage. See “Low voltage power supply (LVPS) with cage removal” on
page 4-41.
3. Remove three screws (A); remove the HVPS cage.
A
Toner present sensor removal
1. Remove the HVPS cage. See “HVPS cage removal” on page 4-42.
2. Remove two screws (A); remove the toner present sensor.
A
4-42 Service Manual
7100-XXX
Toner sensor (receiver) removal
Note: The toner sensor is comprised of two separate parts: the sender and the receiver. The sender
portion of the toner sensor is located on the right side of the MFP. See “Toner sensor (sender) removal”
on page 4-24 for removal.
1. Remove the HVPS cage. See “HVPS cage removal” on page 4-42.
2. Remove 2 screws (A); remove the toner sensor (receiver).
3. Disconnect the toner sensor cable from the connector (B) on the toner sensor (receiver).
Note: The bottom screw is longer than the top screw.
B
A
Left tray guide assembly removal
1. Remove the marker sensor. See “Marker sensor assembly removal” on page 4-47.
2. Remove the HVPS cage. See “HVPS cage removal” on page 4-42.
3. Reroute cable (A) to allow sufficient cable length for removing the left tray guide assembly from the
frame.
A
B
4. Remove two (B) screws that secure the left tray guide assembly to the MFP frame.
Repair information
4-43
7100-XXX
5. Slide the left tray guide assembly out in front of the MFP.
Modem speaker removal
1.
2.
3.
4.
Remove the left rear cover.
Remove the top cover.
Disconnect the modem speaker cable from the system / RIP board.
Remove the old speaker from the interlock assembly by prying the speaker retaining tabs back, and
sliding the speaker out of the interlock assembly.
Fuser fan assembly removal
1.
2.
3.
4.
Remove the left rear cover. See “Left rear cover removal” on page 4-16.
Remove the top cover. See“Top cover assembly removal” on page 4-10.
Remove the system board. See “System board removal” on page 4-36.
Remove the screw (A) that secures the interlock assembly to the printer engine frame. Set the interlock
assembly aside.
A
4-44 Service Manual
7100-XXX
5. Disconnect the fuser fan cable from the connector (B) behind the interlock assembly.
B
6. Remove the top screw (C) that secures the system board cage to the printer frame.
D
C
7. Remove the three screws (D) that secure the fuser fan assembly to the printer engine frame.
8. Lift and remove the fuser fan assembly.
Repair information
4-45
7100-XXX
Modem card removal
1. Remove the rip cage cover.
2. Disconnect the 30-pin cable (A) from the modem card.
B
3. Remove the screws (B) that secure the modem to the RIP cage.
4. Remove the modem.
4-46 Service Manual
A
7100-XXX
Top removals
Marker sensor assembly removal
1.
2.
3.
4.
Remove all the toner cartridges.
Remove the photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-8.
Remove the transfer belt unit. See “Transfer belt unit removal” on page 4-5.
Remove screw (A) from the bracket.
A
5. Disconnect the cable from the sensor, and remove the marker sensor assembly.
Repair information
4-47
7100-XXX
Waste toner auger removal
1.
2.
3.
4.
5.
Remove the photodeveloper cartridge. See “Photodeveloper cartridge removal” on page 4-8.
Remove the transfer belt unit. See “Transfer belt unit removal” on page 4-5.
Remove the top cover assembly. See “Top cover assembly removal” on page 4-10.
Remove the transfer belt cleaning roller. See “Transfer belt cleaning roller removal” on page 4-4.
Remove two screws (A) from the waste toner auger; remove the waste toner auger.
A
Waste toner agitator removal
1. Remove the waste toner auger. See “Waste toner auger removal” on page 4-48.
2. Remove gear (A) from the cleaning roller clutch.
A
3. Pull the agitator off the shaft; lift and remove.
4-48 Service Manual
7100-XXX
Power supply fan removal
1. Remove the top cover assembly. See “Top cover assembly removal” on page 4-10.
2. Disconnect the modem speaker cable from the system board, and carefully route the cable through the
engine board cage.
3. Remove screw (A) from the power supply fan.
A
4. While holding the fan, disconnect the cables (B) from the interlock switches and remove the power
supply fan.
B
Repair information
4-49
7100-XXX
Scanner assembly removals
Flatbed assembly removal
1.
2.
3.
4.
Remove the left rear cover. See “Left rear cover removal” on page 4-16.
Remove the RIP/System board cover. See “System board removal” on page 4-36.
Open the MFP rear cover.
Remove the screws (A) securing the upper left and right covers.
A
A
5. Remove the ADF unit. See “ADF unit removal” on page 4-54.
6. Disconnect the CCD ribbon cable, the operator panel cable, and the flatbed motor cable from the
system board.
4-50 Service Manual
7100-XXX
7. Route all the cables through the RIP cage and around the fuser fan.
8. Remove the ribbon cable guide from the ribbon cable and flatbed unit.
9. Remove the four screws (C) that attach the flatbed to the scanner arms.
C
Repair information
4-51
7100-XXX
10. Tilt the scanner assembly vertically, carefully pulling the white slides off of the flatbed.
11. Lift the flatbed assembly off of the printer engine base.
4-52 Service Manual
7100-XXX
Scanner arm removal
1. Remove the flatbed assembly. See “Flatbed assembly removal” on page 4-50.
2. Remove the screw (A) securing the scanner armlock to the printer top cover.
A
3. Tilt the top of the scanner arm to the center of the MFP, and remove the armlock (B).
Note: Save the armlock for the new scanner arm.
B
4. Continue tilting the scanner arm, and pull the arm outward and up.
5. Lift the scanner arm up and away from the printer top cover.
Repair information
4-53
7100-XXX
6. Repeat steps 3, 4, and 5 for the other arm, if needed.
Note: If you are replacing the scanner arm, remove the spring from the old scanner arm. The spring will go
on the new arm.
ADF unit removal
1.
2.
3.
4.
Remove the upper left rear cover. See “Upper left rear cover removal” on page 4-17.
Remove the left rear cover. See “Left rear cover removal” on page 4-16.
Remove the system board cover.
Remove the screw (B) that secures the ADF, and flatbed ground wires to the RIP cage.
B
5. Disconnect the ADF cable from the system board.
4-54 Service Manual
7100-XXX
6. Remove the ADF cable cover from the rear of the flatbed unit.
7. Route the ADF cable and ADF ground wire through the RIP cage and flatbed unit.
8. Lift the flatbed cover to a vertical position, and up from the flatbed.
Repair information
4-55
7100-XXX
9. With a flat-blade screwdriver, press against the tab on the ADF unit retainer.
10.Lift the ADF unit up and away from the flatbed unit.
Note: Remove the ADF paper tray from the old ADF unit. It will be used on the new ADF unit.
ADF mechanism cover removal
1. Open the ADF top cover, and remove the ADF separator roll and ADF separator pad.
2. Open the flatbed cover.
3. Remove the screw (A) which secures the ADF front cover to the flatbed cover.
Note: When replacing this screw, do not overtighten it.
4-56 Service Manual
7100-XXX
4. Remove the ADF front cover.
5. Remove the screw (B) which secures the ADF separator roll lock to the ADF.
6. Remove the ADF separator roll lock.
7. Remove the two screws (C) which secures the ADF mechanism cover to the ADF.
8. Remove the ADF mechanism cover.
Repair information
4-57
7100-XXX
Operator panel removal
1. Remove the operator panel bezel by prying it off the operator panel cover.
2. Remove the two screws (A).
4-58 Service Manual
7100-XXX
3. Using a flat-blade screwdriver, carefully pry the operator panel away from the scanner assembly in four
places (B).
4. Lift up the operator panel, and disconnect the operator panel cable (C) from the operator panel.
5. Remove the operator panel.
Repair information
4-59
7100-XXX
4-60 Service Manual
7100-XXX
5. Locations and connectors
Printer front and rear views
Locations and connectors
5-1
7100-XXX
Part name
Description
Paper stopper
Stopper for exited papers.
Top cover assembly
Upper enclosure and also the paper exit tray.
Rear cover assembly
Printer rear enclosure that opens allowing clearing of internal paper
jams or maintenance work.
Release lever (rear cover assembly)
Releases rear cover assembly.
Release lever (top cover assembly)
Releases the opening portion of the top cover assembly. Opening the
top cover assembly allows access to the photodeveloper unit.
Right cover
Covers the right side of the printer where the motors and drives are
located.
Front cover
Printer front enclosure that opens allowing toner cartridge or waste
toner bottle replacement.
Paper tray
Standard paper tray that holds printer paper.
Left front cover
Covers the left side of the printer over the MFP engine card.
Left rear cover
Covers the left side of the printer over the RIP card.
Power switch
Turns the printer on and off.
Upper left cover
Covers the fuser fan.
USB connection
Connects the MFP to the host by USB.
Network connection
Connects the printer to an 10/100/1000 base T network.
AC input inlet
Connects the power cord that supplies AC power to the printer.
5-2 Service Manual
7100-XXX
Scanner locations
Callout
Description
1
Paperpath Sensor
2
ADF pick roll assembly
3
ADF separator assembly
4
Cover closed sensor
5
Paper present sensor
6
ADF paper tray
7
Flatbed cover / ADF Assembly
8
Flatbed assembly
9
Operator panel
Locations and connectors
5-3
7100-XXX
Electronic components
Printer engine sensor locations
Name
Code
Paper size sensor
PSU
Detects paper size.
Registration sensor
PT1
Detects whether paper is fed from paper drawer.
Fuser exit sensor
PT2
Detects when paper exits from rear cover assembly.
Tray empty sensor
PEU
Detects if paper is loaded in paper drawer.
OPC marker sensor
PBS
Detects connecting position of OPC belt.
Toner empty sensor
TPD/TTR
Detects if any toner cartridge is empty.
Waste toner sensor
WTS
(LED/TR)
Detects when waste toner bottle is full.
Temperature sensor for fuser
unit
TH
Function
Thermistor that detects fuser temperature.
Output tray full sensor
PFUL
Detects when paper exit tray is full.
Toner key sensor
TNK
Detects presence of toner cartridge.
TDS
Detects toner density of images formed on the transfer belt
surface.
Toner density sensor
Room temperature thermistor
sensor
RTS
Transfer unit sensor
TBS
5-4 Service Manual
Detects ambient room temperature.
Detects irregular rotation of transfer belt.
7100-XXX
MFP circuit board locations
Erase lamp
HVPS
System/RIP
board
Modem/fax
board
LVPS
Engine controller board
Name
Engine controller board
Function
Controls the following MFP processes
Fuser temperature control
Laser output control
Toner empty sensing control
Error processing control
interface control
System/RIP Board
Controls flatbed and ADF functionality
Host connectivity
Controls flatbed and ADF functionality
Operator panel indication
Modem/Fax board
Controls fax transmission and reception.
Erase lamp
Discharges OPC belt located in the photodeveloper cartridge.
Low voltage power supply
(LVPS)
Provides power to control the MFP.
High voltage power supply
(HVPS)
Provides power necessary for the printing
process.
Locations and connectors
5-5
7100-XXX
Fan/motor and interlock switch locations
Name
Code
Function
Main motor
MM
Drives OPC belt and paper transport system.
Developer motors
DM
Drives toner cartridge and developing system.
Scanner motor
Power supply fan
SCM
Drives laser beam scanning in optical unit
PSFAN
Exhausts heat from power
supply unit and interface controller.
Exit fan
EXFAN
Exhausts heat from fusing unit.
Laser fan
LDFAN
Exhausts heat from laser assembly (printhead).
Front interlock switch
DSW1
Paper exit assembly
interlock switch
DSW2
Top interlock switch
DSW3
5-6 Service Manual
Safety interlock switches that break power when covers are opened.
7100-XXX
Clutch locations
Name
Paper feed clutch
Registration clutch
Cleaning roller clutch
Code
Function
PCLU
Feeds paper by coupling feed roller to the main gear unit at the
time of a paper feed.
RECL
Transports paper by coupling registration roller to main gear unit
as synchronized with rotation of transfer belt.
FBCL
Drives the transfer belt cleaner brush by coupling cleaning clutch
to main gear unit at the time of transfer belt cleaning.
TRCL
Cam action clutch that rotates, allowing transfer roller to press
against the back of paper during second transfer. The transfer
roller touching the back of paper causes toner to release from
transfer belt onto paper during second transfer process.
Transfer roller clutch
Locations and connectors
5-7
7100-XXX
Symbol and part name table
Symbol
Part name
Symbol
Part name
BR
Back-up roller
MCTL
Main engine (MCTL P.W.B.)
board
CTFAN
Control fan motor (cooling fan
PS)
MM
Main motor
DM
Developer motor
Optical unit
Optical unit
DPJ
Drum jam sensor
PANEL
Operator panel P.W.B.
DSW1
interlock switch (front)
PBS
Belt sensor
DSW2
interlock switch (top)
PCLU
Upper paper feeding clutch
DSW3
interlock switch (rear)
PDU
PDU P.W.B.
Erase lamp
Erase lamp
PEU
Upper paper empty sensor
FBCL
Cleaning roller solenoid
PFUL
Exit paper full sensor
FBSOL
Cleaning cam clutch
PSU
Upper paper size sensor
FCS
Cleaning roller sensor
PT1
Paper feed sensor
FUSER unit
Fuser unit
PT2
Paper exit sensor
HPSEN
Drum encoder sensor
RECL
Registration clutch
HR
Heater roller
SCM
Scanner motor
HTFAN
Heater fan motor (cooling fan EX)
TBLE
TBFL
Waste toner sensor (WT holder
assembly)
HVU
High voltage unit
TFU1
TFU2
Thermal fuse
LCD
LCD P.W.B.
TH
Themistor
LDU
Laser drive unit P.W.B.
TNK
Toner key sensor
LFU
Lower paper feeding unit
TPD
TTR
Toner empty sensor
LVPS
Power supply unit
TRCM
Transfer cam clutch
5-8 Service Manual
7100-XXX
Engine controller board wiring diagram
Locations and connectors
5-9
7100-XXX
Engine controller board connections
HVCN-21 pin. Connects to HVPS
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
HVUCNCHK-N
12
BRVPWM-N
2
PGND
13
PWMON-N
3
ID [PGND]
14
DCVP-N
4
FCBVPWM-N
15
BRVON-N
5
THV-I
16
+24V -1D
6
DBV [KY] PWM-N
17
+24V -1D
7
THVPWM-N
18
+24V -1D
8
DBV [MC] PWM-N
19
PGND
9
THVRON
20
PGND
10
CBVPWM-N
21
PGND
11
BRVERR
LCN-24 Pin. Connects to LSU assembly
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
+5V - 1R
13
BDT-P
2
LCONT-1
14
LDREF-0
3
LREADY
15
BDT-N
4
LCONT2
16
VCC
5
SGND
17
SGND
6
LDREF-4
18
SGND
7
VIDEO-N
19
SCMRDY-N
8
LDREF-3
20
SCMCLK
9
VIDEO-P
21
PGND
10
LDREF-2
22
SCMON-N
11
SGND
23
+24V-1
12
LDREF-1
24
+3.3V
5-10 Service Manual
7100-XXX
MCN9-14 Pin. Connects to transfer unit, toner density, registration and paper
sensors
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
+5V-S
8
V02:k
2
VCC
9
PTI-N
3
TBEN-N
10
V01-YMC
4
LED
11
SGND
5
SGND
12
+5V-S
6
SGND
13
SGND
7
+5V-S
14
PEV-P
MCN2- 3 Pin. Toner present sensor
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
Toner OK-N
3
SGND
2
+5V-S
MCN10-3Pin. Power supply fan
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
CTFANON-P
3
CTFANERR
2
PGND
MCN7-12 Pin. Marker, paper size, room thermistor
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
PBSEN-N
7
NC (SGND)
2
VCC
8
PSU3
3
+5V-S
9
SGND
4
PSU1
10
PSU4
5
SGND
11
TH3
6
PSU2
12
SGND
MCN1-6 Pin. Exit Fan
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
+5V-S
4
HTFANON-P
2
PT2-N
5
PGND
3
SGND
6
HTFANERR
Locations and connectors
5-11
7100-XXX
MCN4-20 Pin. Clutches, waste toner sensor
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
+24V-1DF3
11
TBFULL-N
2
FBCLON-N
12
SGND
3
13
WTLEDON
4
14
SGND
5
+24V-1DF3
15
+5V-S
6
TRSLON-N
16
DM1SENin
7
+24V-1DF3
17
SGND
8
RECLON-N
18
9
+24V-1DF3
19
10
PKCLU10N-N
20
MCN5-26 Pin. Dev motors 1&2, main motor
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
DM1 OUT
14
MMGAin
2
+24V-1D(B-COM)
15
MMREV-N
3
DM1 OUT
16
MMENC
4
DM1 OUT
17
VCC
5
+24V-1D(A-COM)
18
SGND
6
DM1 OUT
19
PGND
7
DM2 OUT
20
PGND
8
+24V-1D(B-COM)
21
+24V-1D
9
DM2 OUT
22
PGND
10
DM2 OUT
23
+24V-1D
11
+24V-1D(A-COM)
24
MMCLK
12
DM2 OUT
25
MMON-N
13
NC(SGND)
26
MMRDY-N
5-12 Service Manual
7100-XXX
MCN6-14 Pin. LFU
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
LFCN-RET
8
PSCST1
2
+24 - F2
9
PEL1--P
3
PKCLL10N-N
10
OCST1-N
4
NC (SGND)
11
SGND
5
PSL1
12
+5V-S
6
PSL2
13
LFCN-CHK-N
7
PSL3
14
+5V-1
MCN8 - 12 Pin Toner Sensor (TTR, TDP)
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
LEDON-P
7
NC (SGND)
2
TLES (K)-P
8
TLES (C)-P
3
TLESCHK
9
TLESSCN-N
4
TLES (Y)-P
10
SGND
5
SGND
11
ELON-N
6
TLES (M)-P
12
+24V -F2
LVCN-14 Pin LVPS
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
+5V
8
ACSYNC-N
2
+5V
9
+24V
3
+24V
10
PGND
4
NC (SGND)
11
+24V
5
HON
12
PGND
6
ACOFF-P
13
CN-CHK
7
LVPS
14
SGND
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
TH1
4
TH2
2
5
FUTEMP
3
6
SGND
FUCN-6Pin
Locations and connectors
5-13
7100-XXX
POCN-30 Pin. LVPS
Pin #
Voltage / Signal
Pin #
Voltage / Signal
1
+5V - (CNT)
16
SGND
2
PSGNT (CNT)
17
+5V -1
3
+5V - (CNT)
18
SGND
4
PSGNT (CNT)
19
PGND
5
+5V - (CNT)
20
PGND
6
PSGNT (CNT)
21
+24V -1D
7
+3.3V - 2
22
PGND
8
PSGND
23
+24V -1D
9
+3.3V-2
24
PGND
10
PSGND
25
+24V
11
+3.3V - 2
26
PGND
12
PSGND
27
+24V -1D
13
+5V -1
28
PGND
14
SGND
29
+24V
15
+5V -1
30
PGND
5-14 Service Manual
7100-XXX
RIP board
RIP card voltages
Connector / Pin #
Voltage / Signal
J-PNL1/Pin 1
+5V
J-ADF-1/Pin 5
+2.5V
J-FB1/Pin1
+5V
J-CCD / Pin 8
+12V
J-CCD / Pin 10
+5V
J-CCD / Pin12
+3.3
J-CCD / Pin 16
+3.3V
J-CCD / Pin 20
+5V
Locations and connectors
5-15
7100-XXX
Engine controller board
MCN9 MCN8 MCN7 MCN6
1
PACN
1
1
1
1
MCN5
MCN10
1
1
1
FBCN
HVCN
1FCN
MCN4
1
1A
1
1
MCN3
MCN2
MCN1
1
LVCN
1
LCN
POCN
1
FUCN
1
Low voltage power supply (LVPS) board
5-16 Service Manual
1
7100-XXX
High voltage power supply (HVPS) board
Locations and connectors
5-17
7100-XXX
Modem Card voltages and signals
Pin Number
Signal
1
+3.3 V
2
+3.3V
3
Signal
4
Signal
5
Signal
6
Signal
7
Signal
8
Signal
9
Signal
10
Signal
11
Signal
12
Signal
13
Signal
14
Signal
15
Signal
16
Signal
17
SCS3
18
Signal
19
SRD
20
IRQN
21
SWR
22
Signal
23
Reset
24
GND
25
Signal
26
Signal
27
GND
28
GND
29
Signal
30
SSD_PWM
5-18 Service Manual
7100-XXX
6. Preventive maintenance
There is no preventive maintenance performed by a service technician for this printer. Maintenance parts for
the X5xx series MFPs are installed by the customer.
Preventive maintenance
6-1
7100-XXX
6-2 Service Manual
7100-XXX
7. Parts catalog
How to use this parts catalog
• SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the
same list. Common parts are shown by one index number. Parts peculiar to one or the other of the
assemblies are listed separately and identified by description.
• NS: (Not Shown) in the Asm-index column indicates that the part is procurable but is not pictured in the
illustration.
Note: Part 40X4711 - Modem card, is an international part for all geographies.
Parts catalog
7-1
7100-XXX
Assembly 1: Base printer
7-2 Service Manual
7100-XXX
Assembly 1: Base printer
index
P/N
Units
Description
1-1
40X4702
1
ADF separator roll assembly
2
40X4703
1
ADF separator pad
3
40X3383
1
Cover, cleaning roller
4
40X3382
1
Roller, cleaning
5
40X3412
1
Transfer unit
6
40X3418
1
Transfer roller assembly
7
40X4694
1
Paper tray, universal
8
40X0297
1
Power cord, USA
8
40X1766
1
Power cord, LV, USA, APG, Bolivia, Canada, Columbia,
Costa Rica, Ecuador, El Salvador, Guatemala, Honduras,
Mexico, Nicaragua, Panama, Peru, Venezuela
8
40X0301
1
Power cord, HV, Argentina
8
40X1767
1
Power cord, HV, Brazil
8
40X0273
1
Power cord, HV, Chile
8
40X0286
1
Power cord, HV, UK, Ireland
8
40X0278
1
Power cord, HV, Austria, Belgium, Euro English, Finland,
France, Germany, Greece, Netherlands, Norway, Poland,
Portugal, Russia, Slovakia/Czech/Hungary, Spain,
Sweden, Turkey
8
40X0275
1
Power cord, HV, Israel
8
40X0274
1
Power cord, HV, Switzerland French, Switzerland
German, Switzerland Italian
8
40X0276
1
Power cord, HV, South Africa
8
40X0287
1
Power cord, HV, Italy
8
40X0279
1
Power cord, HV, Denmark
NS
40X4716
1
Cover, Legal Extender
Parts catalog
7-3
7100-XXX
Assembly 2: Covers
7-4 Service Manual
7100-XXX
Assembly 2: Covers
index
P/N
Units
Description
2-1
40X4686
1
Cover assembly, top
2
40X4706
1
Arm, scanner (contains the left and right arms)
3
40X4698
1
Cover, top left
4
40X4699
1
Cover, top right
5
40X4692
1
Rear cover assembly (includes 40X3428, and 40X3430)
6
40X3428
1
Assembly, paper exit (contains fuser exit sensor and flag)
7
40X4718
1
Packet, parts
8
40X3430
1
Assembly, registration
9
40X3385
1
Cover, right
10
40X3388
1
Cover, front
11
40X3387
1
Cover, inner front
12
40X4687
1
Cover, front left
13
40X4688
1
Cover, rear left
NS
40X4716
1
Cover, legal extender
Parts catalog
7-5
7100-XXX
Assembly 3: Scanner unit
7-6 Service Manual
7100-XXX
Assembly 3: Scanner Unit
index
P/N
Units
Description
3-1
40X4702
1
Assembly, pick roll
2
40X4703
1
Pad, ADF separator
3
40X4701
1
Assembly, ADF
4
40X4709
1
Cover, ADF mechanism
5
40X4708
1
Tray, ADF input
6
40X4714
1
Cable, ADF
7
40X4713
1
Guide, Cable
8
40X4700
1
Assembly, flatbed
9
40X4693
1
Panel, operator (X 500)
9
40X4695
1
Panel, operator (X 502)
10
40X4721
1
X 500 Bezel, operator panel
10
40X4722
1
X 502 Bezel, operator panel
Parts catalog
7-7
7100-XXX
Assembly 4: Front
7-8 Service Manual
7100-XXX
Assembly 4: Front
index
P/N
3-1
Units
40X3441
Description
1
Cover, laser unit assembly lens
2
40X3400
1
Laser unit assembly (printhead)
3
40X3431
1
Left tray guide assembly with cable (includes paper size
sensor and temperature thermistor)
4
40X3401
1
Right tray guide
5
40X3416
1
Lamp, erase
Parts catalog
7-9
7100-XXX
Assembly 5: Right
7-10 Service Manual
7100-XXX
Assembly 5: Right
index
P/N
Units
Description
4-1
40X3395
1
Gear assembly, main drive
2
40X3391
1
Clutch, registration
3
40X3393
1
Clutch, transfer roller
4
40X3394
1
Clutch, cleaning roller
5
40X4718
1
Packet, parts
6
40X3390
1
Clutch, paper feed
7
40X3397
1
Drive assembly, developer
8
40X3389
1
Motor assembly, main
9
40X3398
1
Assembly, waste toner holder
10
40X3396
1
Waste toner feeder
11
40X3399
1
Sensor, toner, sender TPD (This is a two-piece sensor
system. Ordering of this part number includes both the
right and left side.)
12
40X3432
1
Assembly, interlock switch
Parts catalog
7-11
7100-XXX
Assembly 6: Rear
7-12 Service Manual
7100-XXX
Assembly 6: Rear
index
P/N
Units
Description
5-1
40X3429
1
Assembly, bracket (includes marker sensor (transfer belt
unit), toner density sensor)
2
40X3433
1
Paper guide assembly
3
40X3413
1
Paper guide (C) assembly with cable (includes
registration sensor, tray empty sensor)
4
40X3414
1
Roller, paper feed
5
40X3415
1
Pad, separator
Parts catalog
7-13
7100-XXX
Assembly 7: Left
7-14 Service Manual
7100-XXX
Assembly 7: Left
index
P/N
7-1
Units
40X4696
Description
1
Board, Network RIP
2
40X4711
1
Card, modem (This works worldwide)
3
40X4715
1
Cable, modem
4
40X3405
1
Power supply, high voltage
5
40X3399
1
Sensor, toner, receiver TTR (This is a two-piece sensor
system. Ordering of this part number includes both the
right and left side.)
6
40X3410
1
Sensor, toner present
7
40X4704
1
Power supply, 110 V low voltage
8
40X4705
1
Power supply, 220 V low voltage
9
40X4719
1
Bracket, 110 V power supply
10
40X4720
1
Bracket, 220 V power supply
11
40X4689
1
Board, engine controller
Parts catalog
7-15
7100-XXX
Assembly 8: Top
7-16 Service Manual
7100-XXX
Assembly 8: Top
index
P/N
Units
Description
8-1
40X3402
1
Auger, waste toner
2
40X3403
1
Agitator, waste toner
3
40X3434
1
Assembly, marker sensor (OPC) (includes bracket)
4
40X4691
1
Assembly, fuser fan
5
40X4690
1
Fan, power supply (includes top cover interlock switch
and rear cover assembly interlock switch)
6
40X4710
1
Speaker, modem
Parts catalog
7-17
7100-XXX
Assembly 9: Miscellaneous/Options
7-18 Service Manual
7100-XXX
Assembly 9: Miscellaneous/Options
index
P/N
Units
Description
9-1
40X3421
1
Assembly, secondary paper feed
NS
40X4717
1
Parts packet, harness
NS
40X3442
1
Cable, 120V fuser
NS
40X3443
1
Cable, 240V fuser
NS
40X4718
1
Parts packet, screw
NS
7372640
1
Field relocation kit
NS
14D0403
1
Cable, USB, 2-meter
Parts catalog
7-19
7100-XXX
7-20 Service Manual
7100-XXX
Index
A
Accessing jam areas 3-23
acronyms 1-17
ADF mechanism cover
removal 4-56
ADF paper jams 3-30
ADF unit
removal 4-54
B
bracket assembly
removal 4-30
C
cleaning roller clutch
removal 4-25
cleaning roller cover
removal 4-4
clearances 1-4
clutch
removal 4-27
copy specifications 1-11
CRU/FRU and supplies removals 4-4
D
developer drive assembly
removal 4-22
diagnostic aids 3-1
diagnostic information
printer service checks 2-14
service error codes 2-3
symptom tables 2-11
user attendance messages 2-8
user status messages 2-6
E
emulations 1-6
engine controller board
removal 4-34
wiring diagram 5-9
engine controller board connections 5-10
environment 1-5
erase lamp
removal 4-20
error codes
service 2-3
user attendance messages 2-8
user status messages 2-6
ESD-sensitive parts 4-2
F
fax specifications 1-11
document sizes supported 1-12
miscellaneous 1-12
phone network connectivity 1-11
scan resolutions 1-12
flatbed assembly
removal 4-50
front cover assembly
removal 4-12
front door interlock switch
removal 4-21
fuser aseembly
removal 4-6
fuser fan assembly
removal 4-44
H
handling ESD-sensitive parts 4-2
high voltage power supply
removal 4-40
HVPS cage
removal 4-42
J
jam messages
JAM-A tray, rear (tray 1) 3-24
JAM-A tray, rear (tray 2) 3-26
JAM-B rear 3-27
JAM-C rear 3-29
L
Laser unit assembly
removal 4-18
left front cover
removal 4-15
left rear cover
removal 4-16
left tray guide assembly
removal 4-43
Lithium Information i-xviii
Lithium Warning i-xviii
locations 5-1
circuit boards 5-5
connections
engine card 5-10
modem card 5-18
engine controller board 5-16
fans and motors 5-6
high voltage supply board 5-17
low voltage power supply board 5-16
printer
front and rear view 5-1
RIP board 5-15
scanner 5-3
sensors
printer engine 5-4
solenoids and clutches 5-7
wiring diagram
engine controller board 5-9
Index I-1
7100-XXX
wiring diagram and cable harness reference 5-14
low voltage power supply
removal 4-41
speed dial 3-2
stop/cleat 3-1
output capacities 1-9
M
P
main drive gear assembly
removal 4-27
main motor assembly
removal 4-26
maintenance approach 1-15
inspection and cleaning procedure 1-15
required tools 1-16
serial number 1-16
maintenance mode 3-4
density tune up 3-8
display info 3-4
engine maintenance 3-6
fax maintenance 3-6
print reports 3-5
scan maintenance 3-6
marker sensor assembly
removal 4-47
media guidelines 1-13
envelopes 1-13
glossy 1-14
labels 1-14
paper 1-13
sensing by source 1-14
transparencies 1-13
media input types and weights 1-8
media sizes 1-9
memory configuration 1-3
messages
user attendance 2-8
user status 2-6
models 1-1
modem card
removal 4-46
modem speaker
removal 4-44
packaging and shipping dimensions 1-4
paper and media specifications 1-7
input and output configurations 1-7
print area 1-7
paper exit assembly
removal 4-32
paper feed roller
removal 4-32
paper guide (C) assembly
removal 4-31
paper guide assembly
removal 4-31
paper jam A1 3-24
paper jam A2 3-26
paper jam B rear 3-27
paper jam C rear 3-29
paper jam messages 2-11, 3-22
ADF paper jam 3-30
paper jam A1 3-24
paper jam A2 3-26
paper jam B rear 3-27
paper jam C rear 3-29
part number index X-5
photodeveloper
handling precautions 4-3
photodeveloper cartridge
removal 4-8
physical specifications and weight 1-3
power and electrical specifications 1-4
power supply fan
removal 4-49
preventive maintenance 6-1
print engine specifications
color balance 1-6
emulations 1-6
print resolution 1-6
speed and performance 1-6
time to first print 1-6
printer theory of operation 3-9
Printing the maintenance and configurationn pages 3-3
O
operator panel
alpha/numeric keys 3-1
black start 3-1
color start 3-1
copy LEDs 3-1
directory 3-2
fax LEDs 3-1
hook 3-2
image quality 3-2
LCD display 3-1
menu keys 3-1
reduce/enlarge 3-2
lighter/darker 3-2
re dial 3-2
removal 4-58
scan LEDs 3-1
shift 3-2
-2
Index
R
rear cover assembly
removal 4-14
registration assembly
removal 4-33
removals
ADF mechanism cover 4-56
ADF unit 4-54
bracket assembly 4-30
cleaning roller clutch 4-25
cleaning roller cover 4-4
clutch 4-27
covers 4-10
7100-XXX
developer drive assembly 4-22
engine controller board 4-34
erase lamp 4-20
flatbed assembly 4-50
front cover assembly 4-12
front door interlock switch 4-21
front door interlock switch with bracket 4-21
fuser assembly 4-6
fuser fan assembly 4-44
high voltage power supply (HVPS) 4-40
HVPS cage 4-42
laser unit assembly (printhead) 4-18
left cover 4-15
left rear cover 4-16
left side 4-34
left tray guide assembly 4-43
low voltage power supply (LVPS) 4-41
main drive gear assembly 4-27
main motor assembly 4-26
modem card 4-46
modem speaker 4-44
operator panel 4-58
paper exit assembly 4-32
paper exit unit 4-14
paper feed roller 4-32
paper guide (C) assembly 4-31
paper guide assembly 4-31
photodeveloper cartridge 4-8
power supply fan 4-49
rear 4-30
rear cover assembly 4-14
registration assembly 4-33
right cover 4-13
right side 4-21
scanner arm 4-53
second paper feed assembly 4-9
sensor assembly 4-47
system board 4-36
system board cage 4-39
toner present sensor 4-42
toner sensor (receiver) 4-43
toner sensor (sender) 4-24
top 4-47
top cover assembly 4-10
transfer belt cleaning roller 4-4
transfer belt unit 4-5
transfer roller 4-6
upper left rear cover 4-17
upper right rear cover 4-17
waste toner agitator 4-48
waste toner agitator removal 4-48
waste toner auger 4-48
waste toner bottle 4-7
waste toner bottle holder 4-22
waste toner feeder 4-28
repair information 4-1
required tools 1-16
right cover
removal 4-13
roller spacing 2-69
S
safety information i-xv
scan specifications 1-10
scanner arm
removal 4-53
Scanner calibration and registration 3-3
secondary paper feed assembly
removal 4-9
sensing by source 1-14
serial number 1-16
service checks
ADF paperfeed 2-42
ADF streak 2-41
black page 2-41
cover open 2-35
developer drive assembly 2-16
erase lamp 2-21
flatbed 2-41
fuser assembly 2-24
fuser fan 2-22
fuser thermistor 2-24
high voltage power supply 2-23
HVPS connection 2-25
laser unit assembly 2-25
lower feed unit (paper tray 2) 2-28
lower voltage power supply 2-23
main motor 2-14
missing fuser 2-36
missing photodeveloper cartridge 2-33
missing toner cartridge 2-32
modem / fax card 2-43
network 2-40
OPC belt (photodeveloper) cartridge drive 2-36
OPC belt marker sensor 2-20
operator panel 2-40
paper feed 2-44
paper feed clutch 2-19
paper size sensing 2-37
paper tray missing 2-30
power supply fan 2-22
print quality 2-45
back stain 2-46
background 2-45
banding 2-47
black line 2-48
color misregistration 2-49
insufficient fusing 2-50
insufficient gloss 2-51
jitter 2-52
missing image at edge 2-53
mixed color image 2-54
mottle 2-55
residual image 2-56
ribbing 2-57
smear 2-58
toner drop 2-59
uneven density (right and left) 2-68
vertical line 2-60
Index
3
7100-XXX
vertical staggering image 2-61
vertical white band 2-62
white band 2-63
white line I 2-64
white line II 2-64
white print 2-66
white spot / black spot 2-65
wrinkle / image migration 2-67
printer 2-14
printer no power 2-38
printer paper feed 2-44
registration clutch 2-19
toner empty sensor (receiver-TTR) 2-27
toner empty sensor (sender-TPD) 2-26
toner feed 2-39
toner low / empty 2-31
transfer belt cleaning roller clutch 2-18
transfer belt unit 2-17
transfer roller clutch 2-18
transfer roller missing 2-34
tray empty 2-29
USB 2-40
waste toner bottle 2-31
waste toner feed 2-39
service error codes 2-3
Setting the country code 3-3
spacing table 2-69
specifications 1-2
supported operating systems 1-2
symptom tables
MFP 2-11
print quality 2-13
system board
removal 4-36
system board cage
removal 4-39
T
theory of operation
ep basic 3-9
printer components 3-19
X500 paper path components 3-20
X500 steps in detail 3-11
X500 summary 3-10
time to first print 1-6
toner present sensor
removal 4-42
toner sensor(sender)
removal 4-24
tonser sensor (receiver)
removal 4-43
top cover assembly
removal 4-10
transfer belt cleaning roller
removal 4-4
transfer belt unit
removal 4-5
transfer roller
removal 4-6
-4
Index
U
Understanding the operator panel 3-1
upper right rear cover
removal 4-17
uuper left rear cover
removal 4-17
W
waste toner agitator
removal 4-48
waste toner auger
removal 4-48
waste toner bottle
removal 4-7, 4-22
waste toner feeder
removal 4-28
7100-XXX
Part number index
P/N
14D0403
40X0273
40X0274
40X0275
40X0276
40X0278
40X0279
40X0286
40X0287
40X0297
40X0301
40X1766
40X1767
40X3382
40X3383
40X3385
40X3387
40X3388
40X3389
40X3390
40X3391
40X3393
40X3394
40X3395
40X3396
40X3397
40X3398
40X3399
40X3399
40X3400
40X3401
40X3402
40X3403
40X3405
40X3410
40X3412
40X3413
40X3414
40X3415
40X3416
40X3418
40X3420
40X3421
40X3428
40X3429
40X3430
40X3431
40X3432
40X3433
40X3434
Description
page
Cable, USB, 2-meter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Power cord, HV, Chile - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, HV, Switzerland French, Switzerland German, Switzerland Italian - - - - - - - - - - - - - - - - - - - 7-3
Power cord, HV, Israel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, HV, South Africa - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, HV, Austria, Belgium, Euro English, Finland, France, Germany, Greece, Netherlands, Norway,
Poland, Portugal, Russia, Slovakia/Czech/Hungary, Spain, Sweden, Turkey - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, HV, Denmark - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, HV, UK, Ireland - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, HV, Italy - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, USA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, HV, Argentina - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, LV, USA, APG, Bolivia, Canada, Columbia, Costa Rica, Ecuador, El Salvador, Guatemala,
Honduras, Mexico, Nicaragua, Panama, Peru, Venezuela - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Power cord, HV, Brazil - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Roller, cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Cover, cleaning roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Cover, right - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Cover, inner front - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Cover, front - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Motor assembly, main - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Clutch, paper feed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Clutch, registration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Clutch, transfer roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Clutch, cleaning roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Gear assembly, main drive - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Waste toner feeder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Drive assembly, developer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Assembly, waste toner holder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Sensor, toner, receiver TTR (This is a two-piece sensor system. Ordering of this part number includes both the
right and left side.) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Sensor, toner, sender TPD (This is a two-piece sensor system. Ordering of this part number includes both the
right and left side.) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Laser unit assembly (printhead) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Right tray guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Auger, waste toner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Agitator, waste toner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Power supply, high voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Sensor, toner present - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Transfer unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Paper guide (C) assembly (includes registration sensor, tray empty sensor) - - - - - - - - - - - - - - - - - - - - 7-13
Roller, paper feed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Pad, separator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Lamp, erase - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Transfer roller assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Packet, parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Assembly, secondary paper feed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Assembly, paper exit (contains fuser exit sensor and flag) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Assembly, bracket (includes marker sensor (transfer belt unit), toner density sensor) - - - - - - - - - - - - - 7-13
Assembly, registration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Left tray guide assembly (includes paper size sensor and temperature thermistor) - - - - - - - - - - - - - - - - 7-9
Assembly, interlock switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Paper guide assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Assembly, marker sensor (OPC) (includes bracket) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Part number index
I-5
7100-XXX
40X3441
40X3442
40X3443
40X4686
40X4687
40X4688
40X4689
40X4690
40X4691
40X4692
40X4693
40X4694
40X4695
40X4696
40X4698
40X4699
40X4700
40X4701
40X4702
40X4702
40X4703
40X4704
40X4705
40X4706
40X4708
40X4710
40X4711
40X4713
40X4714
40X4715
40X4716
40X4717
40X4717
40X4717
40X4718
40X4719
40X4720
40X4721
40X4722
7372640
Cover, laser unit assembly lens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Parts packet, harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Parts packet, harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Cover assembly, top - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Cover, front left - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Cover, rear left - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Board, engine controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Fan, power supply (includes top cover and rear cover assembly interlock switches) - - - - - - - - - - - - - - - 7-17
Assembly, fuser fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Rear cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Panel, operator(X500) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Paper tray, universal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Panel, operator(X502) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Board, Network RIP - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Cover, top left - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Cover, top right - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Assembly, flatbed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Assembly, ADF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Assembly, ADF separator roll - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Assembly, pick roll - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Pad, ADF separator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-3, 7-7
Power supply, 110 V low voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Power supply, 220 V low voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Arm, right/left scanner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Tray, ADF input - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Speaker, modem - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Card, modem (Worldwide) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Guide, cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Cable, ADF - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Cable, modem - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Cover, legal extender - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-3, 7-5
Cover, ADF mechanism - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Packet, parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Parts packet, harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Parts packet, screw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Power supply, 110 V low voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Power supply, 220 V low voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Bezel operator panel(X500) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Bezel, operator panel(X502) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Field relocation kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
I-6 Service Manual