Revised: March 24, 2006
Lexmark™ X422 Laser MFP
7001–001
• 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.
7001–001
Edition: March 24, 2006
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
ServiceInfoAndTraining@Lexmark.com. 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, MarkNet, MarkVision, and Optra are trademarks
of Lexmark International, Inc., registered in the United States and/or other countries.
ImageQuick, Optra Forms, and PictureGrade are trademarks of Lexmark International,
Inc.
Other trademarks are the property of their respective owners.
© 2005 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.
U.S.A. P/N 12G9352
7001-001
Table of Contents
Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MFP identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
MFP features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Memory and user flash memory . . . . . . . . . . . . . . . . . . . . . . . 1-4
Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Print area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Data streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Paper handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
MFP speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Resolution and print quality. . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
RIP card specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Scanner features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Copier specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Fax specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . .
Attendance and status messages
Operator panel overview . . . . . . .
Power–on self test (POST) . . .
Symptom tables . . . . . . . . . . . . .
Service error codes . . . . . . . . . . .
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. . . . . 2-1
. . . . . 2-2
. . . . . 2-4
. . . . . 2-5
. . . . . 2-6
. . . . 2-13
iii
7001-001
Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
ADF service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
Cooling fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
Cover interlock switch service check . . . . . . . . . . . . . . . . . . .2-21
Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . .2-22
E-mail service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Low voltage power supply (LVPS) service check. . . . . . . . . .2-24
Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Cold fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Hot fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
Continuity check on HVPS/cartridge . . . . . . . . . . . . . . . . . . .2-29
Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
Network printing service check . . . . . . . . . . . . . . . . . . . . . . .2-31
Operator panel service check. . . . . . . . . . . . . . . . . . . . . . . . .2-32
Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
RIP card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46
Scanner/copier service check . . . . . . . . . . . . . . . . . . . . . . . .2-47
Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
USB service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Solving print quality problems . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
Using print quality test pages . . . . . . . . . . . . . . . . . . . . . . . . .2-49
Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Menu descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Entering the diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Entering the configuration menu . . . . . . . . . . . . . . . . . . . . . . .3-1
Configuration and Diagnostic Menu . . . . . . . . . . . . . . . . . . . . .3-2
Configuration Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Diagnostic mode menu settings . . . . . . . . . . . . . . . . . . . . . . . .3-6
SE Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Hex Trace mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Flashing firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
System shutdown for flashing or other soft resets . . . . . . . . .3-15
Flashing sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Ways to flash the machine . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
iv Service Manual
7001-001
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Paper feed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Printhead alignment adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-2
Printhead registration adjustment . . . . . . . . . . . . . . . . . . . . . . 4-4
Scanner calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Scanner registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
MFP cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
3–pin and 2–pin connectors removal . . . . . . . . . . . . . . . . . . 4-19
Bracket, opener shutter removal. . . . . . . . . . . . . . . . . . . . . . 4-20
Bracket, paper detect (input sensor) removal . . . . . . . . . . . . 4-21
Cartridge coupling assembly removal . . . . . . . . . . . . . . . . . . 4-22
Charge roll removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
D–roll tray 1 feed removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
D–roll (tray 1) shaft assembly removal . . . . . . . . . . . . . . . . . 4-26
Door latches (right side) removal . . . . . . . . . . . . . . . . . . . . . 4-28
Duplex tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . 4-29
Fuser assembly, fuser paper exit guide,
Fuser exit sensor, and fuser lamp removal. . . . . . . . . . . . . . 4-30
HVPS card removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
LVPS card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Lower (MPF) housing assembly removal . . . . . . . . . . . . . . . 4-41
Lower (MPF) housing assembly - paper sensor removal . . . 4-42
Main drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Main drive motor assembly removal . . . . . . . . . . . . . . . . . . . 4-45
Motor assembly (stepper) removal . . . . . . . . . . . . . . . . . . . . 4-46
MPF roller assembly removal . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Pick pad removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Printhead removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Rear exit door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Reference plate assembly removal. . . . . . . . . . . . . . . . . . . . 4-56
RIP card cage (with card in place) removal . . . . . . . . . . . . . 4-58
Smart button sensor removal . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Terminal assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
Tray damper and spring removal . . . . . . . . . . . . . . . . . . . . . 4-65
Transfer roll assembly and left transfer support bearing removal .
4-66
Upper (MPF) housing assembly (with paper flag) removal . . 4-66
v
7001-001
Scanner cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner ADF removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner ADF motor removal. . . . . . . . . . . . . . . . . . . . . . . . .
Scanner assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner CCD carriage removal . . . . . . . . . . . . . . . . . . . . . .
Scanner CCD timing belt removal. . . . . . . . . . . . . . . . . . . . .
Scanner control unit card removal . . . . . . . . . . . . . . . . . . . .
Scanner document tray assembly. . . . . . . . . . . . . . . . . . . . .
Scanner flatbed motor assembly removal. . . . . . . . . . . . . . .
Scanner ADF pick roller assembly removal . . . . . . . . . . . . .
Scanner R1 idler removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner R2 idler removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-67
4-75
4-78
4-79
4-82
4-84
4-86
4-87
4-88
4-91
4-92
4-94
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cables (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Scanner cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
High voltage power supply (HVPS) . . . . . . . . . . . . . . . . . . . . . . 5-8
Low voltage power supply (LVPS) . . . . . . . . . . . . . . . . . . . . . . . 5-9
RIP card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
RIP card assembly (continued) . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
SCU connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Scanner sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1
Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
vi Service Manual
7001-001
Laser notices
The following laser notice labels may be affixed to this MFP as
shown:
Laser advisory label
Laser notices vii
7001-001
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 die Klasse I übersteigen würde,
Menschen keinesfalls erreicht.
viii Service Manual
7001-001
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.
Laser notices ix
7001-001
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.
x Service Manual
7001-001
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.
Laser notices xi
7001-001
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 770795 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.
xii Service Manual
7001-001
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.
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.
Laser notices xiii
7001-001
Japanese Laser Notice
Chinese Laser Notice
xiv Service Manual
7001-001
Korean Laser Notice
Laser notices xv
7001-001
xvi Service Manual
7001-001
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.
Safety information xvii
7001-001
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.
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.
xviii Service Manual
7001-001
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.
Safety information xix
7001-001
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.
xx Service Manual
7001-001
Safety information xxi
7001-001
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 MFP
and the maintenance approach used to repair it. Special tools
and test equipment are listed, as well as general environmental
and safety instructions.
2. Diagnostic information contains an error indicator table,
symptom tables, and service checks used to isolate failing field
replaceable units (FRUs).
3. Diagnostic aids contains tests and checks used to locate or
repeat symptoms of MFP problems.
4. Repair information provides instructions for making MFP
adjustments and removing and installing FRUs.
5. Connector locations uses illustrations to identify the connector
locations and test points on the printer.
6. Preventive maintenance contains the lubrication specifications
and recommendations to prevent problems.
7. Parts catalog contains illustrations and part numbers for
individual FRUs.
Definitions
Note: A note provides additional information.
Warning: A warning identifies something that might damage the
product hardware or software.
CAUTION: A caution identifies something that might cause a
servicer harm.
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.
xxii Service Manual
7001–001
1. General information
The Lexmark™ X422 multifunction product (MFP), with 128MB of
memory standard, a USB port, an integrated Ethernet adapter, and
33.6K baud fax/modem.
This chapter provides an overview of the capabilities of the MFP and
available options for each model.
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. See “Diagnostic information” on page 2-1 for
more information. See “Repair information” on page 4-1 to help
identify parts. After completing the repair, perform tests as needed to
verify the repair.
General information 1-1
7001–001
MFP identification
Options
See “Options” on page 7-22 for a list of options available for the
MFP.
1-2 Service Manual
7001–001
MFP features
Connectivity
Attachments
Standard USB interface
✓
Standard Ethernet 10/100 Base–TX
✓
Fax modem
✓
Note:
✓ Indicates attachment is part of the model factory shipped
configuration.
Fonts
Fonts / options
PCL bitmapped
2
PCL outline
89
PS outline
91
PPDS bitmapped
5
PPDS outline
39
Note: There is no font card support.
General information 1-3
7001–001
Memory and user flash memory
Each model has a standard amount of memory (RAM) soldered on the system
card, and a certain number of 100-pin DIMM slots available for installing
additional memory or user flash memory options.
Memory
Standard memory
Standard flash memory
128MB
None
Memory options
•
•
•
•
•
8MB DIMM
16MB DIMM
32MB DIMM
64MB DIMM
128MB DIMM
Maximum # of memory DIMM
Maximum possible memory
✓
✓
✓
✓
2
384MB
Flash memory options
• 16MB User flash daughter card
• 32MB User flash daughter card
✓
✓
Maximum # of flash daughter cards
1
Maximum possible flash memory
Note: ✓ Indicates option is supported.
1-4 Service Manual
32MB
7001–001
Operator panel
The operator panel consists of a 240 X 64 dot matrix APA LCD and
27 buttons. Four can be illuminated (copy, fax, e-mail and print/
profiles). The display can display eight lines of text with 40
characters each.
Print area
The following print area settings are available.
Print area option
Normal
✓
Edge to edge
✓
General information 1-5
7001–001
Print media
The following table shows the supported media, media weights and
media textures which together provide optimal print quality across a
variety of media.
Media
Paper
✓
Card stock
✓
Transparency
✓
Labels
✓
Envelope
✓
Cotton paper
✓
Bond
✓
Media weights
Heavy
✓
Normal
✓
Light
✓
Media textures
Rough
✓
Normal
✓
Smooth
✓
Note: ✓ Indicates media is supported.
1-6 Service Manual
7001–001
Data streams
Data streams
PCL 6 emulation
✓
PostScript 3 emulation
✓
PPDS
✓
PDF (version 1.3)
✓
Note: ✓ Indicates data stream is supported.
• PCL 6 emulation includes the PCL 5e and PCL XL interpreters,
•
•
and is fully compatible with Hewlett Packard’s LaserJet 5 Family.
Furthermore, the MFP PCL emulation is backward compatible
with the Lexmark T 520/522/620/622 and other members of
Lexmark’s Optra™ family of laser printers.
7001–00x supports version 3010 of the Adobe definition of
PostScript 3, and the interpreter is backward compatible with
the Optra T 520/522/620/622 and other members of Lexmark’s
Optra family of laser printers.
PPDS is backward compatible with Optra T 520/522/620/622
and Lexmark’s Optra family of laser printers. The PPDS
interpreter is inactive as a factory default. It must be activated
using a PJL command or operator panel operation before it can
be used.
General information 1-7
7001–001
Paper handling
Paper handling
Standard
Standard input sources:
• Integrated 250–sheet tray
The 250–sheet drawer supports the
following sizes: A4, A5, JIS B5, folio, letter,
legal, executive, and statement.
• Multipurpose feeder
Standard output destination
2
1
1
1
• 150–sheet sensing bin
1
Standard duplex
✓
Envelope conditioning
✓
Options
Maximum # of optional drawers
1
Optional drawers:
• 250–sheet drawer
• 500–sheet drawer
The 500–sheet drawer supports the
✓
✓
following sizes: A4, JIS B5, folio, letter, legal,
and executive.
Maximum # of media input sources
Maximum input sheet capacity (excluding
envelopes)
3
850
Notes:
• ✓ Indicates associated capability is supported.
• Assumes 20 lb xerographic paper.
• The user must choose between the 250–sheet and
500–sheet optional drawers when adding additional paper
sources.
1-8 Service Manual
7001–001
MFP speed
Speed
Pages/minute in 300 dpi
22
Pages/minute in 600 dpi
22
Pages/minute in 1200 Image Quality (IQ) dpi
22
Time to first print
10 seconds
General information 1-9
7001–001
Resolution and print quality
Note:
• IET, PictureGrade™, print resolution, print darkness, and toner
•
•
•
saver can all be set independently of each other through the
data stream.
Operator panel menus let a user independently set
PictureGrade, and print resolution.
The IET setting is implicitly selected when a particular print
resolution is selected using the Quality Menu.
Toner saver and print darkness settings are implicitly set when a
particular toner darkness is selected using the Quality Menu.
Print quality setting
Print resolution:
• 300 dpi
• 600 dpi
• 1200 IQ dpi
✓
✓
✓
Image Enhancement Technology (IET):
2 Bits/Pel
✓
Toner saver
✓
Print darkness
✓
PictureGrade
✓
Note: ✓ Indicates print quality setting is supported.
1-10 Service Manual
7001–001
RIP card specifications
Feature
Processor
PMC Sierra
RM5231A
Processor/Bus frequency
300/100 MHz
Synchronous DRAM
2–128 Mbit
NAND flash
1–64 Mbit
Processor internal bus width capability
RIP SRAM
64 Bit
0KB
Supplies
Print cartridge
Print cartridges
Average yield
Approximate
coverage
6,000
5%
12,000
5%
General information 1-11
7001–001
Scanner features
Scanner function
Capability
Optical resolution (scan direction)
600 dpi
Optical resolution (feed direction)
300/600 dpi
Scan modes
•
•
•
•
600 scan, 300 feed (mono)
600 scan, 600 feed (mono)
600 scan, 300 feed (color)
600 scan, 600 feed (color)
16 ppm
8 ppm
10 ppm
5 ppm
Maximum ADF paper capacity
50 sheets
Maximum ADF dimensions
8.5 x 14 inches
Maximum flatbed dimensions
8.5 x 11.69 inches
ADF and flatbed paper sizes
•
•
•
•
•
•
•
•
A5
JIS–B5
Executive
Letter
Legal
Folio
Statement
A4
Note: These sizes are supported
without size sensing.
Supported pixel depth
• 1 bit (mono)
• 8 bit (mono)
• 24 bit (color)
1-12 Service Manual
ADF
Flatbed
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
Yes
Yes
Max output resolution (dpi) for
setting
600 x 600
600 x 600
300 x 300
7001–001
Scanner resolutions per mode:
Scanning mode
Output resolution
Optical resolution
Copy (all modes)
600 x 600
600 scan, 300 feed
Fax standard
200 x 100
600 scan, 300 feed
Fax fine
200 x 200
600 scan, 300 feed
Fax super fine
300 x 300
600 scan, 300 feed
Fax ultra fine
400 x 400
600 scan, 600 feed
Scan–to–host
75 dpi 75 x 75
600 scan, 300 feed
Scan–to–host 150 dpi
150 x 150
600 scan, 300 feed
Scan–to–host 200 dpi
200 x 200
600 scan, 300 feed
Scan–to–host 300 dpi
300 x 300
600 scan, 300 feed
Scan–to–host 400 dpi
(mono only)
400 x 400
600 scan, 600 feed
Scan–to–host 600 dpi
(mono only)
600 x 600
600 scan, 600 feed
Copier specifications
Function
Description
Speed
• Simplex - 22 ppm (scan once / print
many)
• Duplex - 12 ppm (scan once / print
many)
Time to first copy
(text / mixed)
• From Power Save - 45 to 80 seconds
• From Stand By / Ready - 20 seconds
Copy resolution
Output resolution - 600 x 600 dpi (based
on a 600 x 300 optical resolution)
Duplex input
Manual
Duplex output
Standard
Collation
Yes
General information 1-13
7001–001
Fax specifications
Function
Description
Transmission rate
Approximately 3 seconds per page
Modem
33.6 kpbs
Compression
MH, MR, MMR, Super G3
Resolution
• 200 x 100 dpi
• 400 x 400 dpi
Speed dial
300 (based on 10–digit phone numbers)
Group fax
Supported by speed dial (shortcuts)
Broadcast
46 locations (based on 10 digit numbers
with a maximum of 512 characters
Manual fax
Yes
Fax from PC
Supported using PS driver for both local
and network attach modes
Serial number
The serial number label is on the inside front cover of the MFP.
Special tools
Long Phillips screwdriver (approximately 6–inch shank)
Slotted screwdriver
Small Phillips screwdriver
When taking voltage readings, always use the MFP frame as ground
unless another ground is specified.
1-14 Service Manual
7001–001
Acronyms
ADF
AFE
ASIC
C
CCD
CCW
CW
DC
DEV
DIMM
DNSFBP
DPI
DRAM
EOLS
FFC
FIGSD
FRU
GND
HVPS
IDE
IET
INA
IQ
KB
KBPS
LCD
LED
LSU
LVPS
MFP
MH
MHz
MMR
MPF
MR
NAND
NVRAM
OPU
Automatic Document Feed
Analog Front End
Application Specific Integrated Circuit
Charge Roll
Charge Couple Device
Counterclockwise
Clockwise
Direct Current
Developer Roll
Dual Inline Memory Module
Danish, Norwegian, Swedish, Finnish, Brazilian
Portuguese
Dots Per Inch
Dynamic Random Access Memory
End Of Line Sensing
Flexible Flat Cable
French, Italian, German, Spanish, Dutch
Field Replaceable Unit
Ground
High Voltage Power Supply
Integrated Development Environment
Image Enhancement Technology
Internal Network Adapter
Image Quality
Kilobyte
Kilobits Per Second (usually as Kbps) /
Kilobytes Per Second (usually as KBps)
Liquid Crystal Display
Light–Emitting Diode
Laser Scanning Unit
Low Voltage Power Supply
Multifunction Product
Message Handling
Megahertz
Modified Modified Read
Multipurpose Feeder
(Modem) Modem Ready
Not And (Gate)
Nonvolatile Random Access Memory
Operator panel Unit
General information 1-15
7001–001
PCB
PCL 6
PJL
POR
POST
PPDS
PS
PWB
RIP
ROM
RS
SCU
SE
T
TAR
USB
V ac
Printed Circuit Board
Printer Command Language
Printer Job Language
Power–On Reset
Power–On Self Test
Personal Printer Data Stream
PostScript
Printed Wiring Board
Raster Image Processor
Read Only Memory
Recommended Standard
Scanner Control Unit
Systems Engineer
Transfer (Roll)
Toner Adder Roll
Universal Serial Bus
Volts Alternating Current
1-16 Service Manual
7001–001
2. Diagnostic information
Start
Unplug power from the MFP before connecting or
disconnecting any cable, assembly, or electronic card.
This is a precaution for personal safety and to prevent
damage to the printer.
This chapter contains the codes and diagnostic tools to aid in
providing corrective action for a malfunctioning MFP.
The status of the machine is displayed on the LCD.
Diagnostic information 2-1
7001–001
Attendance and status messages
Error
code
Attendance message description
Change cartridge invalid refill
Change <source> <new media>
Close door or insert cartridge
Insert Tray 1
Invalid UAA
Load <source> <new media>
Load manual <new media>
Remove standard paper bin
31
Missing or defective print cartridge, replace cartridge
32
Unsupported print cartridge, replace cartridge
34
Short paper
35
Insufficient memory to support Resource Save feature
37
Insufficient memory to collate job
Insufficient memory for Flash Memory Defragment operation
Insufficient memory, some Held Jobs may be lost
38
Memory full
39
Complex page, some data may not have printed
50
PPDS font error
51
Defective flash detected
52
Not enough free space in flash memory for resources
53
Unformatted flash detected
54
Standard Network Software error
2-2 Service Manual
7001–001
Error
code
Attendance message description
55
Unsupported Flash in slot <x>
Unsupported Memory in slot <x>
56
Standard USB Port Disabled
88
Toner low
Scanner ADF cover open
Scanner registration successfully completed
Scanner registration failed
Error
code
Paper jam status messages
200
Paper jam, remove print cartridge to access (MFP input
sensor)
201
Paper jam, remove print cartridge to access (between MFP
input and exit sensor)
202
Paper jam, open rear door to access
230
Paper jam, check duplex
250
Paper jam, check MP feeder
290
Scanner jam, remove all originals from scanner
Replace originals if restarting job
Diagnostic information 2-3
7001–001
Operator panel overview
The X422 operator panel consists of a 240X64 dot matrix APA LCD
and 27 buttons can be illuminated (copy, fax, e-mail and print/
profiles). The display is capable of displaying approximately eight
lines of text with 40 characters each.
The operator panel may be used for:
• Determining MFP status.
• Reviewing MFP settings (See “Configuration Menu Settings”
•
•
•
on page 3-4 for more information.)
Changing MFP settings (See “Configuration Menu Settings”
on page 3-4 for more information.)
Utilizing diagnostic tools (See “Diagnostic mode menu
settings” on page 3-6 for more information.)
Obtaining information about MFP service errors (See “Service
error codes” on page 2-13 for more information.)
2-4 Service Manual
7001–001
Power–on self test (POST)
When you turn the MFP on, it performs a Power–On Self Test. With
all the cables connected, the MFP completes POST between 15–20
seconds in the following sequence:
1. The four blue LEDs light and immediately revert to three
illuminated LEDs.
The display shows a series of dots across the screen. The MFP
is performing the memory test.
2. Then, two LEDs are illuminated and the display shows the
amount of installed memory and processor speed (for example,
128MB 300).
3. Next, one LED is illuminated for a moment.
The display message is ‘Performing Self Test’, the ADF is
tested, the scanner calibrates, and the drive motor and the
printhead motors run.
Note:
• If non-critical sections of NVRAM, or factory defaults ARE
•
•
being restored from the configuration menu, the display
message is ‘RESTORING FACTORY DEFAULTS’ for a
minimum of three seconds.
If the firmware has detected a version change,
‘PERFORMING SELT TEST’ is displayed for a minimum of
three seconds.
If all NVRAM settings are being reset, ‘RESETTING ALL OF
NVRAM’ is displayed for a minimum of three seconds.
Diagnostic information 2-5
7001–001
4. The MFP cycles down, and the home screen is displayed.
Note:
• If errors are detected, an attendance message is displayed.
• If the CCD is locked, a message is posted instructing the
•
•
•
user to unlock the CCD.
If toner is low, a message is displayed.
Cartridge errors are posted if the cartridge is defective or
invalid.
If a cover is open, a message is displayed.
If POST gets to step 2 and hangs for more than 60 seconds, remove
any optional RAM from the RIP card. Restart the machine. If the
problem persists, replace the RIP card.
If POST begins, but the ADF, scanner calibration, and motor test
don’t start, check connections on the RIP card. Replace the RIP
card as necessary.
Symptom tables
Check for correct POST functions of the MFP by observing the
following symptoms:
See “Power–on self test (POST)” on page 2-5 for more
information.
2-6 Service Manual
7001–001
POST symptom table
Symptom
Action
The main motor, cooling fan and
fuser do not come on.
See the “Cover interlock switch
service check” on page 2-21.
POST completes except one or
more lights do not come on.
See the “Operator panel service
check” on page 2-32.
None of the lights come on.
See the “Operator panel service
check” on page 2-32.
Main motor does not come on.
See the “Main motor service
check” on page 2-30.
Fan does not come on.
See the “Cooling fan service
check” on page 2-20.
Fuser lamp does not come on.
See the “Cold fuser service
check” on page 2-26.
Fuser lamp never turns off.
See the “Hot fuser service check”
on page 2-28.
The paper feed picks and tries to
feed paper.
See the “Paper feed service
checks” on page 2-33.
LEDs on operator panel, and
display fail to illuminate. Fan runs
continuously.
See the “Operator panel service
check” on page 2-32.
Scanner locked power off and
Restart message appears when
scanner is unlocked.
See the “Scanner/copier service
check” on page 2-47.
ADF pick roller, or motor does not
run during start up.
See the “ADF service check” on
page 2-19.
operator panel lights function
properly at POST, but the display
is blank.
See the “Operator panel service
check” on page 2-32.
Machine POSTS and enters
operations mode but one or more
buttons are not functioning.
See the “Operator panel service
check” on page 2-32.
Diagnostic information 2-7
7001–001
MFP symptom table
Symptom
Action
Dead machine (no power)
See the “Dead machine service
check” on page 2-22.
Fan noisy or not working
See the “Cooling fan service
check” on page 2-20.
Fuser parts melted
See the “Hot fuser service check”
on page 2-28.
Fuser lamp doesn’t light
See the “Cold fuser service
check” on page 2-26.
Toner not fused to the paper
See the “Poor fusing of image” on
page 2-44.
Blank page
See the “Blank Page” on
page 2-39.
Black page
See the “Black page” on
page 2-41.
Heavy background
See the “Heavy background” on
page 2-42.
Light print
See the “Light print” on page 2-44.
White or black lines or bands
See the “White or black lines or
bands” on page 2-45.
Toner on back of page
See the “Toner on back of page”
on page 2-45.
Paper jams
See the “Paper feed service
checks” on page 2-33.
Main motor noisy or does not
move
See the “Main motor service
check” on page 2-30.
Paper never picks
See the “Paper never picks” on
page 2-37.
Paper feeds continuously
See the “Paper picks during POST
and/or continuously” on
page 2-35.
2-8 Service Manual
7001–001
Symptom
Action
Paper skew
See the Note regarding alignment
on page 4-57 or “Paper feed
service checks” on page 2-33.
MFP not communicating with host
See “Network printing service
check” on page 2-31.
Paper wrinkled or bent
See “Paper “trees,” wrinkles,
stacks poorly or curls” on
page 2-38.
Top cover will not close
See “Cover interlock switch
service check” on page 2-21.
Operator panel button does not
respond
See “Operator panel service
check” on page 2-32 or “RIP card
service check” on page 2-46.
MFP not communicating with host
over network
See “Network printing service
check” on page 2-31.
Diagnostic information 2-9
7001–001
Scanner / copier symptom table
Symptom
Action
Machine boots, but LCD posts a
“Scanner Locked Power off and
Restart” attendance message.
1. Check whether scanner CCD is
locked.
2. Perform scanner service check.
See “Scanner/copier service
check” on page 2-47 for more
information.
Documents don’t feed into ADF.
Scanner jam (290) error.
1. Check for dirty sensors.
2. Check the paper present sensor
(using the scanner sensor test in
diagnostics). Replace as
necessary.
3. Check continuity of scanner –
ADF motor cable.
– If good, replace ADF motor.
– If bad, replace ADF motor
cable.
Paper feeds into ADF, but jams in
the ADF. Error 290 generated.
Perform ADF service check. See
“ADF service check” on page 2-19
for more information.
ADF runs paper through, but no
copy is made. Error 290
generated.
Perform ADF service check. See
“ADF service check” on page 2-19
for more information.
Scanner does not respond to
scan command from attached
computer.
Perform USB service check. See
“USB service check” on page 2-48
for more information.
2-10 Service Manual
7001–001
Symptom
Action
RIP software error on startup.
1. Check the connections on all
cables to the RIP card to the SCU
card.
2. Check for loose connectors, bent
or broken pins on the connectors.
Ensure the individual wires are
secure in the connector.
3. Check connector J32 on RIP card.
• Pin 1 should be +5 V
• Pin 4 should be +24 V
• Pins 2 and 3 are ground
If they pass, check continuity on the
power cable connecting the RIP card
to the SCU.
If they fail, replace the RIP card.
If the cable checks out, replace the
SCU.
If it fails, replace the cable.
Scanner repeatedly gives the user
a “Scan Locked Power off and
Restart” message when the
scanner is actually unlocked.
See “Scanner/copier service
check” on page 2-47 for more
information.
Scanner repeatedly reports 290
error.
See “Scanner/copier service
check” on page 2-47 for more
information.
E-mail symptoms
Symptom
Action
Scanner runs, mail confirmation
failure.
Perform E-mail service check. See
“E-mail service check” on
page 2-23 for more information.
Weblink fails.
1. Check that the FTP server is on
the network.
2. Check the FTP server IP address.
Diagnostic information 2-11
7001–001
Fax symptoms
Symptom
Action
No dial tone.
1. Check that phone line is
connected properly.
2. Check that the phone socket is
working properly. (Test the socket
with a phone.)
Machine dials a number but fails
to make a connection with
another fax machine.
The other fax machine may be
turned off. Ask the fax recipient to
check their machine.
Incoming fax has blank spaces or
poor quality.
1. The sending fax machine may be
faulty.
2. The sending fax machine may
have a dirty document glass.
3. A noisy phone line can cause
errors.
4. Check the MFP print quality by
making a copy.
5. The print cartridge may be empty.
Replace as necessary.
Some words on an incoming fax
are stretched.
The sending fax machine had a
temporary jam.
Documents are not stored in
memory.
Document does not feed.
2-12 Service Manual
• There may not be enough
memory to store the document.
• The machine may display an
‘Insufficient Memory’ message.
• Wait for current jobs to process.
• Delete any print and hold jobs that
are not needed.
• Install more memory.
1. Make sure the document is not
wrinkled and that it has been
inserted correctly.
2. Check that the document is the
correct size.
7001–001
Service error codes
Service error codes are generally non–recoverable except in an
intermittent condition when a POR of the MFP temporarily recovers
from the error condition.
Error code
Description
Action
900 – RIP software
error
Internal RIP software
error on the system
card.
Replace the system
card.
902 – Engine software
error
General internal engine
software error on the
system card.
Replace the system
card.
920 – Fuser error
Fuser below
temperature when
printing.
921 – Fuser error
Fuser below standby
temperature in idle.
922 – Fuser error
Fuser failed to reach
standby temperature.
Perform cold fuser
service check to isolate
the problem to:
- Fuser lamp
- Lamp cable
- Complete fuser
(thermistor)
923 – Fuser error
Fuser too hot during
printing or in idle.
924 – Fuser error
Open circuit in
thermistor path.
925 – Fuser error
Incorrect fuser lamp
installed.
929 – Toner sensor
Indicates a problem
with either the toner
sensor or print
cartridge.
LVPS
Perform hot fuser
service check to isolate
the problem to:
- Fuser lamp
- Complete fuser
(thermistor)
Test the toner sensor
using the "Base Sensor
Test" in the diagnostic
menu.
• If the test fails,
replace the sensor.
• If the test passes,
replace the
cartridge.
Diagnostic information 2-13
7001–001
Error code
Description
Action
931 – Printhead error
No first Hsync.
Inspect the printhead
cable for continuity /
connection.
If the inspection
passes, replace the
printhead.
932 – Printhead error
Lost Hsync.
Inspect the printhead
cable for continuity /
connection.
If the inspection
passes, replace the
printhead.
935 – Printhead error
Mirror motor unable to
reach operating speed.
Perform voltage check
on printhead connector
of the RIP card.
If the voltages are
incorrect, replace the
card.
Inspect the printhead
cable for continuity /
connection.
If the inspection
passes, replace the
printhead.
936 – Transport motor
Transport motor initial
lock failure.
937 – Transport motor
Transport motor lost
lock.
Inspect motor, cabling
and main drive
assembly.
Replace defective
parts.
939 – RIP - engine
communications
RIP processor cannot
communicate with
engine processor on
RIP card.
Replace RIP card
assembly.
940 – LVPS (Low
Voltage Power Supply)
There is a failure with
the zero crossing signal
on the line controlling
the fuser lamp.
Ensure the proper
LVPS is installed.
2-14 Service Manual
7001–001
Error code
Description
Action
941 – Image pipeline
An error was detected
with the image pipeline
ASIC on the RIP card.
Observe debug data of
engine microcode.
Replace RIP card
assembly, if necessary.
942 – Scanner failure
Communication failure.
RIP card cannot
establish
communications with
the scanner card.
943 – Scanner failure
Carriage mechanical
failure.
Inspect the RIP–SCU
cable for proper
connection and
conductivity.
If the inspection
passes, replace the
SCU card.
Check the mechanical
movement of the CCD
carriage.
Replace the defective
component.
944 – Scanner failure
Lamp failure.
One or both of the
lamps failed, or the
CCD cable has failed.
945 – Scanner failure
CCD failure.
Check the CCD cable
for proper connection
and connectivity.
If inspection passes,
replace the CCD
carriage.
The CCD circuit on the
CCD carriage has
failed or the CCD cable
has a problem.
946 – Scanner failure
CCD calibration error.
Perform the scanner
calibration process.
Check the CCD cable
for proper connection
and connectivity.
If inspection passes,
replace the CCD
carriage.
Diagnostic information 2-15
7001–001
Error code
Description
Action
947 – Modem failure
Modem card, on the
RIP card, experienced
a failure.
Replace RIP card
assembly.
948 – Fax storage
Flash partition too
small on modem card.
949 – Fax storage
Flash partition invalid
or not available.
Reformat from the
configuration menu.
If the problem persists,
replace the RIP card
assembly.
NVRAM CRC error
detected. "n" indicates
where the error
occurred.
POR the machine to
clear the error.
953 – NVRAM failure
NVRAM chip failure.
Replace the operator
panel.
954 – NVRAM failure
NVRAM CRC failure.
955 – Code CRC
Code ROM and NAND
failed the CRC check,
or NAND experienced
an uncorrectable multibit failure.
Replace the RIP card.
956 – System board
Processor failure.
Replace the RIP card.
957 – System board
ASIC failure.
Replace the RIP card.
958 – NAND failure
Indicates the system
has performed more
than 100 shift and
re-flash operations as a
result of ECC bit
corrections.
Replace the RIP card.
959 – System board
SRAM failure.
Replace the RIP card.
960 – Memory error
RAM soldered on RIP
card has failed.
Replace the RIP card.
961 – Memory error
RAM in slot 1 is
defective.
Replace the DIMM in
slot 1.
952 – NV failure: n
2-16 Service Manual
If the problem persists,
replace the operator
panel.
7001–001
Error code
Description
Action
962 – Memory error
RAM in slot 2 is
defective.
Replace the DIMM in
slot 2.
965 – Panel failure
The engine is
experiencing failures
sending commands to
the operator panel.
Inspect the operator
panel RIP cable for
connectivity and
continuity.
If the cable passes,
replace the operator
panel.
If the cable fails,
replace the RIP card.
976 – Standard
network
Unrecoverable software
error in the network
port.
Replace the RIP card.
Diagnostic information 2-17
7001–001
Service checks
Service checks involve measuring voltages of the LVPS,
HVPS, SCU, and RIP card assemblies. Continuity and
resistance verifications are done on cables and
components as required.
Note: When looking at the printed side of a PCB, connectors are
designated with “J” followed by a number. On the SCU card, the
connectors are designated with a CN followed by a number. Pin 1 is
designated on the PCB by an adjacent “1” or triangle. Pin numbers
index sequentially to the opposite end of the connector. See “RIP
card assembly” on page 5-10 for more information.
2-18 Service Manual
7001–001
ADF service check
FRU
Action
ADF assembly
SCU card
1. Open the ADF cover and check for
obstructions in the paper path.
2. Check the sensors to ensure the
flags move freely or dust is not
blocking the sensors.
If the ADF makes a copy and
generates a 290 error after the last
sheet is fed through the ADF, and
the error only goes away after a
POR, replace the ADF.
• If the problem persists, replace
the SCU.
If the ADF starts feeding, but prints a
blank page generating a 290 error,
the paper may or may not feed all
the way through the ADF.
• POR the machine into diagnostics
mode and perform a scanner
sensor test on the paper present
sensor and the ADF cover sensor.
• If the ADF cover sensor remains
in the CL setting when actuated
and the paper position sensor
remains in the OP setting when
actuated, replace the SCU card.
• If the ADF cover sensor changes
to the OP setting when actuated,
replace the ADF.
Paper in the ADF does not feed,
a blank page is run from the printer.
Paper in the ADF does not feed,
a 290 error is generated.
Check CN5, pins 1 and 2 for +24V.
• If +24V, replace the ADF motor
assembly.
• If not +24V, replace the SCU.
ADF pick roller, and ADF motor not
running during POST.
Check CN5, pins 1 and 2 for +24V.
• If +24V, replace the ADF motor
assembly.
• If not +24V, replace the SCU.
Diagnostic information 2-19
7001–001
Cooling fan service check
FRU
Action
Cooling fan
Make sure the cooling fan motor
cable plug is properly seated.
Turn the MFP off and disconnect the
cooling fan cable at the cooling fan.
Turn the MFP on. Within
approximately 15 seconds the RIP
card assembly should apply +24V dc
to the fan. See “RIP card
assembly” on page 5-10 for more
information.
• If voltage is present, replace the
cooling fan.
• If voltage is not present,
disconnect the cable from the RIP
card (J30) and check for continuity
and shorts (connector sockets 1
and 2).
– If the cable is good, see the
“RIP card service check” on
page 2-46 for more
information.
– If the cable is damaged,
replace the cable.
2-20 Service Manual
7001–001
Cover interlock switch service check
Note: Make sure a print cartridge is installed and the cover closes
all the way, engaging the cover open switch lever.
FRU
Action
Cover interlock switch
Disconnect the cover interlock cable
from the interlock switch.
Push the cover interlock switch to
the closed position and verify
continuity between the bottom and
middle terminals.
Open the switch and verify continuity
between the bottom and top
terminals. The top and middle
terminals indicate discontinuity at all
times.
• If the switch is good, verify
+5 V dc on the middle spade of
the cable and ground on the top
spade of the cable.
• If voltage is not present, see “RIP
card service check” on
page 2-46.
Replace the switch if faulty.
Diagnostic information 2-21
7001–001
Dead machine service check
Perform this service check when there is no activity at power up.
FRU
Action
LVPS
RIP card
Main wiring harness
Ensure the MFP is plugged in.
Note: Check the AC line voltage.
Voltage should be within the
following limits:
– 100 V ac - 127 V ac for the
nominal - 110 V model printer
– 200 V ac - 240 V ac for the
nominal- 220 V model printer
• If the line voltage checks out,
perform the LVPS service check.
See “Low voltage power supply
(LVPS) service check” on
page 2-24 for more information.
• If the line voltage fails, replace the
LVPS.
If the LVPS passes, check the
continuity of the cable from CN2 on
the LVPS.
• If the cable checks out, replace
the RIP card.
• If the cable fails, replace the main
harness assembly.
Note: Before replacing the RIP card,
inspect the wiring around and behind
the RIP cage for signs of damaged
insulation. A short can cause the
device to not start.
2-22 Service Manual
7001–001
E-mail service check
FRU
Action
Have customer verify the e-mail
settings using the MFP’s built in Web
server.
Check X422 User’s Reference for
setting instructions.
Note: Failure to connect to the Web
server may indicate a problem with
either the network or the NIC on the
MFP.
If the e-mail settings check out,
perform the network printing service
check. See “Network printing
service check” on page 2-31 for
more information.
Diagnostic information 2-23
7001–001
Low voltage power supply (LVPS) service check
FRU
Action
Low voltage power supply card
(LVPS) (110 V and 220 V)
Unplug the power cord and verify
that the cable is correct and
functioning. Replace if necessary.
With the power cord unplugged,
disconnect the 12–pin and 4–pin
connectors from the LVPS.
• On the 12–pin connector (pin 1 is
closest to the HVPS), verify pins
1, 2, 7, 8, and 9 are ground.
Re–plug the power cord and turn the
MFP on.
CAUTION: Be careful to not
ground pins to cage while
testing.
• Verify pins 5 and 6 are +5 V dc.
• Verify pins 10, 11 and 12 are
+24 V dc.
• Verify pin 1 of the 4–pin connector
(also closest to the HVPS) is
+5 V dc.
If any one of these are incorrect,
replace the LVPS.
2-24 Service Manual
7001–001
Fuser service check
When toner is partially fused to the paper, it is usually caused by low
fuser temperature.
Warning: Avoid handling the lamp as much as possible as it is
easily broken. Be careful not to touch the glass housing with bare
hands, as skin contains acids that can weaken the glass.
The line voltage to the MFP must be within the following limits:
• 100 V ac–127 V ac for the nominal–110 V model MFP
• 200 V ac–240 V ac for the nominal–220 V model MFP
Diagnostic information 2-25
7001–001
Cold fuser service check
FRU
Action
Fuser lamp
Lamp cable
LVPS
Unplug the MFP and disconnect the
fuser lamp cable from the LVPS card
connector (CN3). See “Low voltage
power supply (LVPS)” on page 5-9
for more information.
Note: Ensure the proper lamp is
installed.
Check for continuity across the fuser
lamp. (Pins 1 and 2)
If there is continuity, go to step 1. If
there is no continuity, go to step 2.
Step 1: Continuity
Reconnect the fuser lamp cable at
CN3.
Re–plug and turn the MFP on.
Measure the voltage at connector CN4
on the LVPS. It should match the line
voltage.
• If line voltage is not present, replace
the LVPS.
Make sure the fuser thermistor is
correctly connected to the RIP card
(J29). If the problem persists,
disconnect the thermistor cable from
the RIP card assembly and check for
+4 V to +5 V dc. See “Locations” on
page 5-1 for more information.
• If the voltage is incorrect, see “RIP
card service check” on page 2-46.
Step 2: No Continuity
Unplug the MFP and check the lamp
cable for continuity.
• If correct, replace the lamp.
• If incorrect, replace the lamp cable.
2-26 Service Manual
7001–001
Make sure the correct voltage lamp is installed. The voltage rating is
stamped on one of the lamp contacts.
FRU
Action
Fuser assembly
If the fuser lamp comes on and a
fuser failure error code displays, be
sure the thermistor is contacting the
hot roll and the thermistor cable is
firmly seated in connector J29 on the
RIP card assembly. (The thermistor
cable goes through the frame by way
of a connector.)
Check for excessive toner buildup on
the surface of the thermistor. Clean
as necessary.
Unplug the MFP and disconnect the
thermistor cable from the RIP card
(J29).
Measure the resistance of the
thermistor. The resistance measures
approximately 245K ohms when cool
(approximately 40°C) and
2K–3K ohms hot.
Replace the fuser assembly as
necessary.
Diagnostic information 2-27
7001–001
Hot fuser service check
Make sure the correct voltage lamp is installed. The voltage rating is
stamped on one of the lamp contacts.
FRU
Action
Lamp
Unplug the MFP and make sure the
termister is properly connected in
J29 on the RIP card. Measure the
resistance of the thermistor.
Fuser assembly
The resistance measures
approximately 245K ohms when cool
(approximately 40°C) and
2K–3K ohms hot.
Replace the fuser assembly as
necessary.
2-28 Service Manual
7001–001
Continuity check on HVPS/cartridge
Continuity between the HVPS and the charge roll, Dr. B (blade), TAR
(toner adder roll), the developer roll, and the photoconductor (DC)
can be checked as follows:
FRU
Action
HVPS
Left guide assembly
Cartridge contacts
1. Turn MFP off.
2. Remove the right side cover.
See “Right side cover
removal” on page 4-13 for
more information.
3. Remove the print cartridge.
4. Check from C on the HVPS to
the bearing on the left side of
the charge roll. See “High
voltage power supply
(HVPS)” on page 5-8 for more
information.
5. Check from the Dr. B, TAR,
DEV, T, and DC
(photoconductor) respectively
to the corresponding pin on
the right side frame where the
print cartridge makes its
contacts.
• If any show discontinuity,
remove the HVPS and check
the cartridge contact
assemblies (springs) for
continuity and damage.
• If the charge roll and the cable
at C show discontinuity,
replace the left guide
assembly. See “High voltage
power supply (HVPS)” on
page 5-8 for testing the PCB.
Diagnostic information 2-29
7001–001
Main motor service check
FRU
Action
Main motor
Main motor cable
Verify +24 V dc on pin 7 at J14 on
the RIP card assembly.
• If the voltage is correct, check the
main motor cable for continuity.
• If the voltages are not correct, see
“Low voltage power supply
(LVPS) service check” on
page 2-24 or replace the RIP card
assembly.
Note: Always check printhead
alignment after replacing the RIP
card assembly. See “Printhead
alignment adjustment” on
page 4-2 for hardware alignment
of the printhead.
If continuity exists on each wire,
replace the main motor.
If continuity does not exist on one or
more of the wires, replace the motor
cable.
2-30 Service Manual
7001–001
Network printing service check
FRU
Action
RIP card
1. Check the lights on the MFP NIC.
• If the lights work, ping the IP
address of the MFP.
Note: The IP address is in the
TCP/IP menu nested in the
Network/USB menu in the
Administrator menu.
• If the lights to the NIC are not
lighting up, test the MFP with a
network cable that is known to
work.
• If the lights do not illuminate with a
known good cable, replace the
RIP card.
• If the IP address of the MFP is
169.254.xxx.xxx and the
customers network uses DHCP to
assign IP addresses, have the
network administrator manually
assign an address to the MFP.
Ping the manually assigned
address.
• If this fails, call tech support to see
if there is a firmware update to
address this issue. If the firmware
does not resolve the issue,
replace the RIP card.
Diagnostic information 2-31
7001–001
Operator panel service check
Inspect the operator panel cable for damage. Make sure the cable is
plugged in securely.
Run POST and check each light for proper operation.
FRU
Action
Operator panel
OPU - RIP cable
RIP card
1. Check J6 on the RIP card
assembly.
Verify +5V on pins 1, 2, 15, 23,
and 24.
•If any pin does not have +5V,
replace the RIP card.
2. Check the OPU-RIP cable for
continuity. Replace as necessary.
3. If the RIP card and operator panel
cable check out, replace the
operator panel.
4. Perform operator panel test in
diagnostics mode. Replace
operator panel as necessary.
2-32 Service Manual
7001–001
Paper feed service checks
Paper picks and advances approximately 4 inches
FRU
Action
Plate assembly (reference edge)
Paper feed gear
Drive assembly
Turn MFP off and remove the print
cartridge and left side cover.
With a left finger, rotate the main
motor counterclockwise while using
a right finger to resist gear
movement in the plate assembly
(reference edge) in the paper path
below the cartridge.
If the gear motion can be stopped
while continuing to rotate the drive
motor, one of the units has to be
replaced. The paper feed gear is
most likely the failing part.
Remove the drive assembly for
further inspection. Replace the faulty
unit.
When the plate assembly is
replaced, it has to be adjusted. See
“Paper feed adjustment” on
page 4-2 for more information.
Diagnostic information 2-33
7001–001
Paper jam error indication during POST
FRU
Action
Stack control flags
Photo sensor
If the exit sensor flag is not resting
within the paper exit sensor during
POST, the MFP indicates Remove
paper from standard output bin.
Perform a base sensor test to ensure
the exit sensor is operating correctly.
Make sure the flag is operating
freely.
Replace the photo sensor and/or the
stack control flag as necessary.
Photo sensors (paper path)
Make sure the input paperfeed
sensor is working properly. A stuck
or incorrectly installed sensor
causes this error.
• 200 Paper Jam. Remove print
cartridge to check for paper,
damaged flags, or malfunctioning
sensors.
• 201 Paper Jam. Remove print
cartridge to access and check
under and/or inside the rear door
for jammed paper.
• 202 Paper Jam. Open rear door
and check for a damaged flag,
malfunctioning sensor at the fuser
exit, or a paper jam inside the rear
door.
• 250 Check MP Feeder. Check for
paper jam in the MPF or a
malfunctioning MPF sensor.
• 230 Paper Jam. Check the
sensor in the duplex path for a jam
or a malfunction.
2-34 Service Manual
7001–001
Paper picks during POST and/or continuously
FRU
Action
Paper feed assembly
Paper feed solenoid
Check the pick roller clutch for wear.
The solenoid interacts with the
clutch controlling motion of the pick
roller.
If the cam surface of the pick roller
clutch assembly is worn, the
solenoid may not stop the D–roll
(pick roll) from rotating. Replace the
paper feed assembly if necessary.
Make sure the spring on the solenoid
is properly installed. If the spring is
improperly installed or missing, the
pick roller will continuously pick
paper.
Replace the solenoid.
Diagnostic information 2-35
7001–001
Paper picks but stops half way through the MFP
FRU
Action
Input paper feed sensor
RIP card assembly
Perform base sensor test to ensure
the input paper feed sensor is
working properly.
Check for a broken or stuck flag on
the input paper feed sensor.
Make sure the cable is seated on the
RIP card assembly (J31).
Verify +5 V dc on pins 1, 4, 7, and
ground on pins 3, 6, and 9. See
“Locations” on page 5-1 for more
information.
• If correct, replace the input paper
feed sensor.
• If the voltage is not correct,
replace the RIP card assembly.
Note: Always check printhead
alignment after replacing the RIP
card assembly. See “Printhead
alignment adjustment” on
page 4-2 for hardware alignment
of the printhead.
2-36 Service Manual
7001–001
Paper never picks
FRU
Action
Paper tray
Make sure the paper tray and paper
are correctly positioned.
Check the input tray for missing or
broken parts.
Replace the tray as necessary.
Paper feed solenoid
RIP card assembly
Make sure solenoid is installed
correctly and its cable is plugged into
the RIP card assembly. See
“Locations” on page 5-1 for more
information.
• Verify approximately 40 ohms in
the solenoid. If not correct,
replace the solenoid.
• Verify the solenoid has the spring
in place and functions
mechanically. If this is true and the
resistance is correct, replace the
RIP card assembly.
Note: Always check printhead
alignment after replacing the RIP
card assembly. See “Printhead
alignment adjustment” on
page 4-2 for hardware alignment
of the printhead.
Diagnostic information 2-37
7001–001
Paper occasionally picks or picks multiple sheets at once
FRU
Action
Paper feed roll
D–roll at Tray 1 spring
Paper feed assembly
Check the paper feed roll (D–roll/pick
roll) for wear. Replace as necessary.
Verify that the extension spring is
working properly. If not, replace the
spring.
If the paper feed roll shaft rotates
freely, replace the paper feed
assembly.
Note: We recommend that the paper
feed roll be replaced when the paper
feed assembly is replaced.
Paper “trees,” wrinkles, stacks poorly or curls
FRU
Action
Fuser assembly
This problem is most likely due to a
worn backup roller. A worn backup
roller causes the MFP to run hotter
than required for the media being
printed. Excessive heat can cause
paper treeing problems, poor
stacking, or curl.
2-38 Service Manual
7001–001
Print quality service checks
Blank Page
FRU
Action
Print cartridge
Remove the print cartridge and
gently shake the assembly to evenly
distribute the toner.
Ensure clean electrical contacts on
the right side.
Printhead
Printhead cable
HVPS
RIP card assembly
Cartridge contacts assembly
Blank pages can be caused by a
defective printhead assembly, high
voltage power supply, or RIP card
assembly. See “RIP card service
check” on page 2-46 and verify the
required voltages and proper ground
at connectors J1 and J3.
With the cartridge removed and the
MFP off, check continuity between
HVPS (DC designation on outside of
card) and the PC pin inside the
printer. The PC pin is directly above
the transfer roll gear.
Diagnostic information 2-39
7001–001
FRU
Action
(continued)
If the voltages are correct, check the
printhead cable for continuity.
Printhead
Printhead cable
HVPS
RIP card assembly
Cartridge contacts assembly
• If the cable measures continuity,
replace the printhead.
• If the cable does not measure
continuity, replace the cable.
See “High voltage power supply
(HVPS)” on page 5-8 and verify the
voltages.
• If the +24 V dc and +5 V dc input
voltage measurements are
correct, replace the HVPS.
• If the voltages are incorrect,
replace the RIP card assembly.
Note: Always check printhead
alignment after replacing the RIP
card assembly. See “Printhead
alignment adjustment” on
page 4-2 for hardware alignment
of the printhead.
2-40 Service Manual
7001–001
Black page
Note: Incorrect laser exposure or incorrect charging of the
photoconductor by the charge roll causes an all black page.
FRU
Action
HVPS contacts
Check the contacts for
contamination and correct
installation. Replace as necessary.
RIP card assembly
Controller card
HVPS cable
HVPS
Left guide assembly
Ensure the HVPS to RIP card and
charge roll cables are correctly
installed.
Check continuity of the charge roll
cable from C (printed on outside
HVPS) to the bushing at the right
side of the charge roll.
• If continuity fails, replace the left
guide assembly.
Check continuity from the charge roll
left side bushing to the right side
shaft.
• If continuity fails, remove the
charge roll and clean the left side
shaft and bushing.
See “High voltage power supply
(HVPS)” on page 5-8 and check the
voltage measurements.
• If the +24 V dc and +5 V dc input
voltages are correct, replace the
HVPS.
• If the voltages are not correct, see
“RIP card service check” on
page 2-46.
• Check continuity on the HVPS/
RIP card cable.
Diagnostic information 2-41
7001–001
Heavy background
Poor development or poorly charged toner particles cause excessive
background. This is more noticeable as the print cartridge nears end
of life.
FRU
Action
Print cartridge (not a FRU)
Make sure the print cartridge is
correctly installed and the high
voltage contacts are clean.
If the cartridge is installed correctly
and the problem persists, try a new
cartridge.
HVPS contacts
HVPS card
RIP card assembly
Cartridge contacts assembly
Check the contacts for correct
installation and contamination where
contact is made with the print
cartridge and HVPS card. Clean as
necessary.
If this does not correct the problem,
replace the following FRUs one at a
time in the order shown:
• HVPS card
• RIP card assembly
Note: Always check printhead
alignment after replacing the RIP
card assembly. See “Printhead
alignment adjustment” on
page 4-2 for hardware alignment
of the printhead.
2-42 Service Manual
7001–001
Partial blank image/white spots (no periodic pattern)
FRU
Action
Print cartridge (not a FRU)
Remove the print cartridge and
gently shake the assembly to evenly
distribute the toner.
If the print cartridge is low, try a new
one.
Fuser backup roll springs
(not a FRU)
Fuser assembly
Check springs at each end of the
backup roller to ensure adequate
and even pressure is applied to the
fuser hot roll. Replace the fuser if
necessary.
Paper
Make sure recommended paper is
being used.
Variation in image density horizontally across page
FRU
Action
Print cartridge
The charge roll may have an
unbalanced pressure against the PC
drum. Check for equal forces at both
ends of the charge roll.
Try a new print cartridge.
Transfer (roll)/bearings
Transfer assembly roll
Check the springs and bearings at
both ends of the transfer roller. The
bearing assemblies should support
the transfer roller, applying even
pressure to the PC drum.
Replace both bearing assemblies if
either spring shows signs of damage
or fatigue.
Inspect the transfer roller for signs of
wear or damage and replace as
necessary.
Diagnostic information 2-43
7001–001
Poor fusing of image
FRU
Action
Fuser lamp
The fuser may not be operating at
the proper temperature to fuse the
toner to the paper. See “Cold fuser
service check” on page 2-26.
Make sure recommended paper is
being used.
Light print
FRU
Action
Print cartridge
Make sure the print cartridge is
installed correctly and is not low on
toner.
If the problem continues, install a
new print cartridge.
Transfer roller
HVPS contact (transfer roller)
HVPS card
Check the transfer roller for signs of
toner buildup and contamination.
Inspect the HVPS contact (transfer
roller) for contamination.
Inspect the HVPS card for
contamination where it meets the
HVPS contacts.
If all components appear free of
contamination, replace the following
FRUs one at a time in the order
shown:
• Transfer roller
• HVPS contact (transfer roller)
• HVPS card
2-44 Service Manual
7001–001
White or black lines or bands
FRU
Action
Print cartridge
Paper feed drive gears
Banding appears as light or dark
horizontal lines on a uniformly gray
page or on a page with a large area
of graphics. Banding is primarily due
to a variation in the speed of the
paper as it feeds through the MFP
especially in the developer and
transfer process. Inspect the print
cartridge and paper feed
components, especially the drive
gears, for signs of wear, debris,
binds, or damage.
Toner on back of page
FRU
Action
Print cartridge
Inspect the overall paper path for
signs of spilled toner.
Gently clean the contaminated areas
with a soft cloth or compressed air.
Fuser assembly
The fuser hot roll can cause toner on
the back of the paper, if toner is
building up on the hot roll. This
buildup may transfer to the backup
roller, later transferring to the back of
the paper.
Inspect the hot roll and backup roller
for signs of contamination and
replace fuser assembly as
necessary.
Transfer roller
A transfer roller contaminated with
toner can cause toner to transfer to
the back of printed pages.
Inspect the transfer roller for
contamination and replace as
necessary.
Diagnostic information 2-45
7001–001
RIP card service check
FRU
Action
RIP card assembly
Check for +24 V dc from the LVPS
card to the RIP card assembly.
• Turn the MFP off.
• Disconnect the LVPS cable from
the RIP card at J28.
• Turn the MFP on.
Verify +24 V dc from the cable,
pins 1, 2, and 10.
• If voltages are not present or
incorrect, see the “Low voltage
power supply (LVPS) service
check” on page 2-24 for more
information.
Note: Always check printhead
alignment after replacing the RIP
card assembly. See “Printhead
alignment adjustment” on
page 4-2 for hardware alignment
of the printhead.
Note: U.S. versus non–U.S. and
the MFP configuration ID can be
reset. See “Diagnostic mode
menu settings” on page 3-6 for
more information.
2-46 Service Manual
7001–001
Scanner/copier service check
FRU
Action
CCD
FFC (CCD) cable assembly
SCU card assembly
1. Open the flatbed cover and restart
the MFP.
If the CCD illuminates but does
not move, check pins 2 and 5 on
CN6 on the SCU card for +24V.
• If it passes, replace the flatbed
motor.
• If it fails, replace the SCU.
If the CCD lamp fails to illuminate,
but the CCD moves, check the
FFC cable connector on the SCU.
Pins 16, 17, 21, and 22 should
measure +12V.
If it passes, check the cable
continuity.
– Continuity, replace the CCD.
– No continuity, replace the
cable.
If the lamp illuminates and the
CCD moves, perform the CCD
home sensor test. See
“Diagnostic mode menu
settings” on page 3-6 for more
information.
• If the test fails, replace the CCD.
Diagnostic information 2-47
7001–001
Transfer roll service check
FRU
Action
Transfer assembly roll
Transfer Bearing
Check the springs in the left and
right transfer roll bearings. The
bearing assemblies should support
the transfer roll, applying even
pressure to the PC drum. The roll
should rotate evenly and smoothly.
Replace both the transfer roll
bearing assemblies if the springs or
bearings indicate damage or lack of
proper function.
Inspect the transfer roll for signs of
wear or damage and replace as
necessary.
USB service check
FRU
Action
USB cable
1. Try a different USB cable.
If changing the cable does not fix the
problem, proceed with step 2.
2. With the MFP attached to the
computer, run the USB view utility.
• If the USB view utility indicates
that the MFP is attached and
communicating with the PC
(bMaxPacketSize0>0), there may
be a problem with the PC.
• If the USB port is faulty, the utility
shows the bMaxPacketSize0 at 0,
and the connection status variable
shows Device failed enumeration.
Replace the RIP card as
necessary.
2-48 Service Manual
7001–001
Solving print quality problems
Using print quality test pages
To help isolate print quality problems, like streaking, print test pages
using the print quality test pages setting:
1. Enter the special function menu. See “Entering the
diagnostics menu” on page 3-1 for more information.
2. Scroll to the print tests menu item and press Select.
3. Scroll to the print quality test, and press Select.
Three pages print to help you evaluate print quality. The first
page is the print quality test page, the second page is gray, and
the third page is black. Once the paper exits into the output bin,
the MFP returns to the print quality test menu item. Exit
diagnostics to return to the Ready state.
4. Use the test pages to isolate problems such as print too light,
toner streaks, and so on. See the Troubleshooting tables in the
User’s Reference for solutions to these problems.
5. To return the MFP online, POR the printer.
Problem
Action
Light or blurred characters.
The print cartridge may be getting
low on toner:
• Remove the print cartridge.
• Shake it from side to side to
redistribute the toner.
• Reinstall it.
• Make sure you are using
recommended print media (see
media types and sizes in the
User’s Reference.)
• Use MarkVision™ to define the
custom type setting for media
type, media texture, or media
weight.
• The print cartridge may be
defective. Replace it.
Diagnostic information 2-49
7001–001
Problem
Action
Toner smudges appear on the
front or back of the page.
• Make sure the paper is straight
and unwrinkled.
• Check for loose toner in the
printer.
• Clean the printer.
• If the problem persists, replace
the cartridge.
Vertical or horizontal streaks
appear on the page.
• Replace the print cartridge.
Toner smears or rubs off the
page.
• Try a different kind of paper. Paper
designed for copiers gives the
best quality.
• If you are printing on special
media, such as, card stock or
labels, be sure you select the
correct paper type in the MFP
driver.
• Change the media texture setting.
You can download the latest driver
from the Lexmark Web site,
www.lexmark.com.
The print is getting light but the
display is not indicating toner low.
• Remove the print cartridge and
gently shake it from side to side to
redistribute the toner.
• Replace the print cartridge.
2-50 Service Manual
7001–001
Problem
Action
The display indicates Toner Low
attendance message.
• Remove the print cartridge and
gently shake it from side to side to
redistribute the toner.
• Replace the print cartridge.
Solid black areas on
transparencies or paper contains
white streaks.
• Choose a different fill pattern in
your software application.
• Try a different type of paper. Paper
designed for copiers gives the
best quality.
• Remove the print cartridge and
gently shake it from side to side to
redistribute the toner.
• Replace the print cartridge.
Faint images or repetitive spots
appear on the page.
• Select a different media type or
form type setting from your MFP
driver.
• Try a different type of paper. Paper
designed for copiers gives the
best quality.
• Replace the print cartridge.
Pages are blank.
• The print cartridge may be out of
toner or defective. Replace the
cartridge.
• You may have a software error. Try
turning the MFP off and back on.
• Check the photoconductor circuit
for continuity.
• Check the printhead.
The operator panel lights do not
come on when the MFP is turned
on.
• The lights may take a few seconds
to come on.
• Make sure the power cord is firmly
plugged in at the back of the MFP
and at the electrical outlet.
The top cover does not close.
Make sure the print cartridge is
positioned correctly.
Diagnostic information 2-51
7001–001
Problem
Action
The MFP is on, but nothing prints.
• Make sure the print cartridge is
installed properly.
• Make sure the network or USB
cable is firmly plugged into the
connector on the back of the
printer.
• POR the machine, enter
diagnostic mode and perform a
print test to determine whether the
problem is with the MFP or the
computer.
– If you can print a test
page, the problem is in
the computer or the
software application.
– If you cannot print a test
page, the problem is in
the printer.
If printing from the network, perform
the network printing service check.
The media skews or buckles.
• Don’t overfill tray 1 or the optional
tray 2 (see media capacities in the
media types and sizes table in the
User’s Reference).
• Make sure the paper guides are
flush against the edges of the
media.
The paper sticks together/MFP
feeds multiple sheets of paper.
• Remove the paper from tray 1 or
the optional tray 2 and fan the
paper.
• Don’t overfill tray 1 or the optional
tray 2 (see media capacities in the
media types and sizes chart in the
User’s Reference).
The paper fails to feed from tray 1.
• Remove the paper from tray 1 and
fan the paper.
• Make sure tray 1 is selected from
the MFP driver.
• Do not overfill the tray.
2-52 Service Manual
7001–001
Problem
The paper fails to feed from the
optional tray 2.
Action
• Make sure the optional tray 2 is
selected from the MFP driver.
• Remove the paper from the
optional tray 2 and fan the paper.
• Make sure the tray is pushed all
the way in.
• Make sure the metal plate is
pressed down before inserting it
into the printer.
Note: Once the tray is inserted,
the metal plate springs up so the
paper can feed into the printer.
• Make sure the paper does not
exceed the stack height indicator.
• Make sure the paper is under both
corner bucklers (see loading
paper in the User’s Reference).
The display indicates Tray 2 even
though there is paper loaded in
the optional tray 2.
• Make sure the tray is pushed all
the way in.
• Press Select.
The MFP does not print after a
paper jam has been cleared.
• Press Select or open and close
the MFP cover to restart the
printer.
• Make sure the print cartridge is
installed properly.
Diagnostic information 2-53
7001–001
Problem
Unexpected characters print or
characters are missing.
2-54 Service Manual
Action
• Make sure you are using the
correct MFP driver.
• Select hex trace mode to
determine what the problem is.
See “Hex Trace mode” on
page 3-13 for more information.
• Restore factory defaults. See
“Factory defaults” on page 3-4
for more information.
• Make sure the network cable or
USB cable is firmly plugged in at
the back of the printer.
7001–001
3. Diagnostic aids
Menu descriptions
The Configuration Menu contains menus, settings and operations.
These menus are used to configure a MFP for operation. This menu
is accessed via a POR sequence.
The Diagnostics Menu contains settings and operations used while
manufacturing the printer. This menu is accessed via a POR
sequence. See “Configuration and Diagnostic Menu” on
page 3-2 for more information.
Entering the diagnostics menu
1. Press Start, Stop, and Clear buttons and start the MFP.
2. Hold the buttons down until “Performing Self Test” is displayed
on the LCD.
3. Release the buttons, and “Registration” is displayed.
Entering the configuration menu
1. Press Start and Stop buttons and start the MFP.
2. Hold the buttons down until “Performing Self Test” is displayed
on the LCD.
3. Release the buttons, and “Configuration Menu” is displayed.
Diagnostic aids 3-1
7001–001
Configuration and Diagnostic Menu
When the Configuration Menu is accessed, the following screen is
displayed:
✓ Prt Quality Pgs
Panel1 Menus
PPDS Emulation
Factory Defaults
Energy Conserve
Min Copy Memory
Exit Config Menu
When the diagnostic menu is successfully accessed, the
REGISTRATION menu appears as default.
REGISTRATION
3-2 Service Manual
7001–001
Moving around the menus
Configuration menu
To scroll around the configuration menu, use the up and down
navigation keys on the operator panel.
To select an item on the menu, scroll to the item, and press the
Select button.
Note: A check mark to the left of the menu item indicates it is active.
After a menu item has been selected, use the right and left
navigation keys to toggle between selections. To select an item,
scroll to the item, and press Select.
To exit the configuration menu, scroll to the bottom until the Exit
Configuration Menu box is highlighted with a solid black line. Press
Select. The machine performs a POR.
Diagnostic menu
To navigate menu items in the diagnostic menu, use the left and right
navigation keys on the operator panel. Press the Select button for
the desired menu item. A submenu is presented with more choices.
Use the left and right navigation keys to navigate the submenu.
To exit a submenu, press the up navigation key.
To exit diagnostics, use the up navigation key to scroll to the top level
of the diagnostics menu. Use the right navigation key to scroll to
EXIT DIAGNOSTICS. Press Select. The machine performs a POR.
Diagnostic aids 3-3
7001–001
Configuration Menu Settings
The Print Quality Pages menu is used to check print quality. Three
test pages are presented for inspecting print quality.
Panel Menus
The Configuration menu is used to change MFP settings. It enables
or disables user access to the panel menus. Disabling Panel Menus
keeps users from altering settings via the operator panel. This panel
is used by the administrator.
PPDS emulation
The Configuration menu activates and deactivates PPDS emulation.
Factory defaults
Sets the MFP parameters to the factory settings.
To restore factory defaults:
1. POR the machine into Configuration Mode. See “Entering the
configuration menu” on page 3-1 for more information.
2. Use the down navigation button to scroll to the RESTORE
FACTORY DEFAULTS item on the menu.
3. Press Select. The machine performs a POR.
4. The RESTORE FACTORY DEFAULTS sets the MFP non critical
parameters back to the factory settings.
Note: Some settings are not affected: panel language, energy
conserve, paper prompts, registration margins, and page count.
3-4 Service Manual
7001–001
Energy conserve
Adjusts the settings on the power saver menu.
Minimum copy memory
Selects the minimum amount of memory to allocate for copy jobs.
Note: The memory available is always less than or equal to the
amount of installed memory.
Format fax flash
Formats flash memory for fax jobs.
Paper prompts
Sets the source to feed paper for media and sizes not already
assigned to input sources.
Note: Choices are: auto, multipurpose feeder, and manual paper.
• Auto mode, the source defaults to where the print job is
allocated to.
Note: Default media type & size is changed to the specific job
media type & size once prompted to load media.
• Multipurpose feeder mode, the user is prompted to load media
in the feeder.
Note: Default media type & size is changed to the specific job
media type & size once prompted to load media.
• Manual paper mode, the user is prompted to load media in the
feeder.
Diagnostic aids 3-5
7001–001
Envelope prompts
Same as paper prompts, but applies only to envelopes.
Print error log
Printed error log.
Note:
– Debug and secondary 900 error codes are included in the
error log report available in the Diagnostic Mode.
– Debug and secondary 900 error codes are not included in
this error log printout (since the configuration mode may be
accessed by an end user).
Diagnostic mode menu settings
Registration
Sets the top, bottom, left and right registration margins for the print
engine. The numeric value for each setting is measured in 1/600th of
an inch. The MFP registration process is described in Chapter 4.
See “Printhead registration adjustment” on page 4-4 for more
information.
Print tests
Performed to verify the MFP can print from each of the installed print
sources. Print Quality pages can also be printed when using this
test.
Scanner tests
Includes the following tests and functions:
Calibration - Performs a baseline gray scale calibration of the CCD
assembly within the scanner. This function is performed
automatically upon exit of Diagnostic Mode at next POR. No
insertion of paper is required as the calibration uses a white
reference strip inside of the scanner housing.
3-6 Service Manual
7001–001
Registration - Performs scanner margin adjustments for ADF and
flatbed. Registration can be adjusted automatically or manually.
Manual mode is somewhat difficult; automatic mode is
recommended. Automatic mode finds the top and left edge of paper
from a sample scan and calculates right and bottom margins
settings. A special sheet of colored paper is required for successful
registration of the ADF. This special media is available as a FRU as
well as included with FRUs requiring registration adjustment upon
replacement. The scanner registration process is described in
Chapter 4. See “Scanner registration” on page 4-5 for more
information.
Feed Tests - Verifies the ADF feeds paper and measures the page
length for specific paper sizes. This test is also used to scan the
entire length of the flatbed.
Note: By indicating paper size, paper length should be within a
specific range (which is used for determining paper jams when
out of range).
While performing the feed test:
• When paper is detected in the ADF, the paper is fed through
the ADF for the ADF portion of the feed test.
• When paper is not detected in the ADF, the flatbed CCD
carriage traverses the entire length of the flatbed repeatedly.
Pressing Select or Stop cancels the feed test.
Note: The number of pages through the flatbed and ADF that
passed or failed is displayed at the end of the test.
Sensor test
Allows manual inspection of the following sensors:
•
•
•
•
•
ADF paper present sensor
ADF paper path sensor
ADF cover open sensor
Flatbed cover open sensor
CCD home position sensor
Diagnostic aids 3-7
7001–001
ASIC test
Checks the scanner ASIC memory.
Hardware Tests
Panel test
Performs a series of LCD and button tests on the operator panel.
DRAM test
Checks the DRAM memory (both soldered down and optional
DRAM).
Duplex tests
Duplex quick test
Checks that the back side duplex top margin setting is correct. A
duplexed version of the quick test page is printed (the back side can
be used in adjusting the duplex top margin).
Duplex top margin
Allows adjustment of the back side top margin.
Input tray test
Observes the paper path while media is fed through from various
input sources.
Notes:
• The lower front door can be opened during this test to observe
•
the paper path.
The upper front door cannot be opened during this test as it
supports the charge roll.
3-8 Service Manual
7001–001
Base sensor tests
Checks the following sensors:
•
•
•
•
•
•
•
•
Toner optical sensor
Input
Output
Narrow media
Upper front door open
Tray 1 sensor (only displayed if Tray 2 option is installed)
MP feeder paper present sensor
Bin full sensor
To perform the base sensor test:
1. Enter diagnostics mode. See “Entering the diagnostics
menu” on page 3-1 for more information.
2. Scroll to base sensor test.
3. Press Select.
4. Scroll to the desired sensor for testing.
5. Press Select.
6. Open and close the circuit by moving the actuator for each
sensor.
Note: For the toner sensor, use a thin object (thin blade
screwdriver, piece of paper) to close the sensors light path.
When the sensor is selected from the menu, CL or OP will be
the two indicators of the sensors state. A defective sensor is
unable to switch between the two states.
7. After completing the test, press the up navigation button twice
and use the right navigation button to scroll to the EXIT
diagnostics menu item.
8. Press Select.
9. The machine performs a POR.
Note: If a sensor is defective, and replacing it does not fix the
problem, the RIP card or SCU card could be defective. See “RIP
card service check” on page 2-46 and/or “Scanner/copier
service check” on page 2-47 for more information.
Diagnostic aids 3-9
7001–001
MFP Setup
Defaults
Allows the defaults set at the factory to be selected from either the
U.S. set or non-U.S. set.
Print menus
Prints a diagnostic menus page.
Page count
Displays the page count which can be reset by an SE.
Perm page count
Displays the permanent page count and cannot be reset.
Configuration ID
Displays the configuration ID. Press Select to activate, use the left
and right navigation keys to increase or decrease the numbers.
When the desired number is reached, press Select to advance to
the next digit. Repeat for each digit. After all digits are set, the
machine performs a POR.
U.S.
0x000303
EMEA
0x100304
Note: The configuration ID is also in this menu.
Model name
Displays the model name.
3-10 Service Manual
7001–001
Modem type
Setting for various modem types. There are two values that can be
chosen based on the installed RIP card.
U.S. card
•
•
•
•
USA / Canada
Czech Republic
Japan
Rest of World
Non U.S. card
•
•
•
•
Europe
Australia
New Zealand
South Africa
Error log
Prints an error log that contains 900 error code information, and
debugging information.
Diagnostic aids 3-11
7001–001
SE Menu
The X422 utilizes an SE menu used for diagnosing.
Note: DO NOT CHANGE ANY SETTINGS IN THIS MENU
WITHOUT CONSULTING THE TECHNICAL SUPPORT CENTER
FIRST. Changing some of the settings could render the MFP
unusable.
The menu is accessed by pressing **411 while in operating mode.
Menu items are accessed by pressing the menu items number.
There are four options that can be viewed in the SE menu.
1. Code Levels
Shows the SE the firmware files installed. This can be useful in
diagnosing a problem with the Support Center. The files
installed are displayed as follows:
– Base
– Kernel
– Engine
– Loader
– Network
– Fax
2. Agency Test Menu
Not to be altered in the field.
3. Fax Settings
– V.34 Mode - enables or disables the use of this transmission
protocol.
– Detect end of line sensing (EOLS) - sets the EOLS sensing
capability.
– Dial Mode - enables or disables tone or pulse dialing.
– Send Memory - sets the amount of memory that can be used
when sending a fax.
– Receive Memory - sets the amount of memory that can be
set aside for receiving a fax.
– Memory use setting - enables or disables the use of the
memory settings above.
– Print T.30 Log. - prints a log of fax transmissions. Can be
used for debugging a session.
3-12 Service Manual
7001–001
4. Modem Settings
– Dial Timeout - used to determine the amount of time before
disconnecting, if the fax on the receiving end is not
functioning.
– Transmit Level - sets the transmission signal level on the
modem.
– Receive Threshold - used to determine what is a valid
transmission.
Hex Trace mode
The MFP can be set to hex trace to perform troubleshooting tasks.
To enter hex trace mode:
1.
2.
3.
4.
5.
6.
Press the administration button on the operator panel.
When the menu appears, select the default menus item.
From the default menu item, select the MFP settings menu.
In the MFP settings menu, select Utilities.
In the Utilities menu select Hex Trace.
Hex trace is indicated on the home screen.
To exit hex trace mode, POR the machine.
Diagnostic aids 3-13
7001–001
Flashing firmware
Note: Only perform firmware flashing when told to do so by
Technical Support.
Flash file types - Basic packages available to flash a machine.
The packages in the files:
•
•
•
•
•
•
•
•
Kernel - kernel for the printer.
Page4 - applications for MFP functions
Copy - applications for MFP copy functions
Scan - applications for MFP scan to host functions
Network - applications and drivers for network functions
Fax - applications for MFP fax functions
Engine - engine firmware
SCU - scanner control unit firmware
DLE - applications for downloadable emulator functions (IPDS, IQ ImageQuick™, BC - Bar Code)
Which files contain which packages:
•
•
•
•
Fullnet.fls - kernel, page4, copy, scan, network, fax
Updbase.fls - page4, copy, scan
Updnet.fls - kernel, network, fax
Updeng.fls - engine
– Updscan.fls - SCU
3-14 Service Manual
7001–001
System shutdown for flashing or other soft resets
When a flash file is received (or other soft resets occur), the various
subsystems shut down as follows:
• All pages stored in the printers memory that are queued for
•
•
•
printing must be printed before the flash operation can begin.
If a scanner job is active, the Scan subsystem flushes all pages
from the ADF.
If a fax is active, the Fax subsystem hangs up the phone
immediately. Pages that have been acknowledged as being
received will be restored from NAND flash and printed after the
next POR.
If a Scan-to-Network/Scan-to-USB operation is active, the
connection is closed immediately.
Diagnostic aids 3-15
7001–001
Flashing sequence
Once the system has terminated all activities, previous described,
the following flash sequence begins:
1. The panel will display progress as the flash data is read over
one of the host interfaces.
2. After a data segment is read in, a CRC is computed. The
success or failure of that CRC is posted on the panel.
– If the CRC fails, the device automatically reboots after a few
seconds.
3. Steps 1 and 2 are repeated for each segment of data in the
flash file. (There are generally two.)
4. After all data is read into memory (assuming no errors have
occurred), the Flash Kernel takes over control, and all other
applications are no longer able to execute.
5. The Flash Kernel operates the panel in text mode to display
progress as the NAND Flash is programmed.
Note: The "DO NOT POWER OFF" message (translated)
should remain intact on the bottom half of the panel.
6. Once all partitions have been programmed, the device
automatically reboots.
3-16 Service Manual
7001–001
Ways to flash the machine
Using FTP
1. Boot the MFP into normal operating mode.
2. Get IP address to machine by going into the printers
administration menu and selecting TCP/IP.
3. FTP to the MFP using a FTP client.
4. Place the first file on the machine by issuing a put command.
The machine goes through the flash sequence.
5. After the machine reboots, repeat steps 2 and 3 as needed.
Using the Web server on the printer
1. When the firmware files are where you can access them from a
PC, open a Web browser and point it to the MFP IP address.
2. Press the configuration button on the Web page.
3. Press the update code link under other settings.
4. When the security warning pops up, press Yes.
5. In the Java applet that opens up, browse to the file you want to
use to flash the printer.
6. Press the Flash button. The machine goes through the flash
sequence and reboots.
7. Repeat the process as needed with other files.
Diagnostic aids 3-17
7001–001
USB
1. Open the USB Utility.
2. Browse for flash file.
3-18 Service Manual
7001–001
3. Select the MFP from the list of printers installed on the
computer. Note: The X422 must be installed via USB on the
computer you are performing the firmware flash procedure.
(Select your printer here)
4. Press Start.
5. Repeat the process for all the files needing to be updated.
Diagnostic aids 3-19
7001–001
3-20 Service Manual
7001–001
4. Repair information
Warning: Read the following before handling electronic parts.
Handling ESD-sensitive parts
Many electronic products use parts that are known to be sensitive to
electrostatic discharge (ESD). To prevent damage to ESD-sensitive
parts, follow the instructions below in addition to all the usual
precautions, such as turning off power before removing logic 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
printer.
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 printer.
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 ESDsensitive 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 coldweather heating is used because low humidity increases static
electricity.
Repair information 4-1
7001–001
Adjustments
Paper feed adjustment
A
When a reference plate (reference edge) assembly is removed, it
requires alignment. Use a long shank (6–inch) Phillips screwdriver to
adjust the rear screw holding the assembly in place. It is accessed
through the hole in the main drive assembly [A], located between
the RIP card cage and the main motor PCB. Adjust the screw
counterclockwise which rotates paper counterclockwise in the MFP
path (image clockwise) and vice versa.
Printhead alignment adjustment
Note: Whenever the printhead is removed or if a new printhead is
installed, this procedure must be performed.
4-2 Service Manual
7001–001
1. Install printhead into MFP and snug screws just enough to hold
printhead to frame. Screws do not need to be tight as screws
may be loosened to make printhead position adjustments.
2. Replace the top cover, and the scanner unit. Do not
permanently fasten the top cover and scanner unit to the MFP
frame. Replace cables as shown.
3. Power on the MFP in diagnostics mode. See “Entering the
diagnostics menu” on page 3-1 for more information.
4. Select the Registration menu and press the Start button to print
the Quick Test pages.
5. Shutdown the printer.
6. Remove the scanner unit, and the top cover assembly.
See “Top cover assembly removal” on page 4-17 for more
information. Do not remove top cover completely.
7. Inspect the Quick Test page.
– If the alignment is satisfactory, tighten the printhead screws
and proceed to next step.
– If the alignment is not satisfactory, loosen the screws and
adjust the printhead as needed. Slightly tighten the screws
again and repeat steps 2 through 7.
8. Tighten the screws on the printhead.
9. Reassemble entire unit in reverse order of disassembly.
Repair information 4-3
7001–001
Printhead registration adjustment
1. Power on the MFP in diagnostics mode. See “Entering the
diagnostics menu” on page 3-1 for more information.
2. Select Registration by pressing the Select button on the
operator panel.
Registration is the default item appearing on the diagnostics
menu.
The registration screen appears. There are four items.
– T = xxx, the setting for the top margin,
– B = xxx, the setting for the bottom margin.
– L = xxx, the setting for the left margin.
– R = xxx the setting for the right margin.
This is the sequence in which they are adjusted.
3. Starting with the top margin setting, use the left or right
navigation keys to adjust the setting up or down.
Registration is adjusted 1/600 of an inch each time the left or
right navigation key is pressed.
4. When the desired setting is reached, press the Select button.
Pressing Select advances to the next margin setting. Repeat
step 3 for the bottom, left, and right margins.
5. Press the Start button to verify the margin settings by printing a
quick test page.
Printing a quick test page saves the new margin settings. After
the quick test page is printed, the registration screen is
displayed.
6. Exit diagnostics mode.
The MFP restarts in operating mode.
4-4 Service Manual
7001–001
Scanner calibration
Select Calibration from the scanner tests in the diagnostics menu.
See “Diagnostic mode menu settings” on page 3-6 for more
information. After diagnostics is exited, the calibration test is
performed automatically on the next MFP POR.
Perform the scanner calibration when:
• The ADF assembly, CCD, RIP card or SCU card is replaced.
• NVRAM is reset.
• The operator panel is replaced.
Scanner registration
Automatic registration
Note: Before performing scanner registration, ensure MFP
registration and alignment is properly set. See “Printhead
alignment adjustment” on page 4-2 and “Printhead
registration adjustment” on page 4-4 for more information.
1. Place a white piece of paper (A4 or letter) on the flatbed.
2. Place a colored piece of paper in the ADF, making sure the
edge guides are properly adjusted.
Note: Use a light blue sheet of paper for the ADF registration. Product
Assurance obtained the best results using Cascade MP Colors Blue
20 lb. paper (Boise Cascade part P1-MP-2201-BE). A moderate
density blue paper should work if this paper cannot be found.
3. Select Registration from the scanner tests menu in the
diagnostics menu.
4. Select Auto Detect.
5. Specify the size of the colored paper, in the ADF.
6. The machine performs a POR.
7. When the machine completes POR, the test runs, the display
indicates the test is active.
8. After the registration test is complete, success or failure is
indicated on the display.
9. Verify the results by running a copy of a quick test page created
during MFP registration. See “Print tests” on page 3-6 for
more information.
Repair information 4-5
7001–001
Manual registration
Note: Manual registration should be performed only after automatic
registration is performed. The primary purpose of manual
registration is to fine-tune the automatic adjustments already
made.
1. Select Manual from the scanner registration menu.
2. Scroll through the four margins and adjust the desired
margin(s).
Note: Adjust the margin by pressing the left and right
navigation buttons.
3. Press the Select button.
4. A scan copy of the last MFP registration must be run to verify
the settings.
Lubrication
Several FRUs must be lubricated when installed. The following
diagrams indicate which units and where to place the lubricant.
Place a drop size or less at each location and then rotate the gears
or mechanism to evenly distribute the lubricant. Use Nyogel 744
(P/N 99A0394) or IBM 23 (P/N 99A0462).
4-6 Service Manual
7001–001
P/N 56P0633
P/N 56P0637
Repair information 4-7
7001–001
P/N 56P0635
P/N 56P0636
Reassembly
Ensure all cables are reconnected when reassembling the printer.
The MFP may not detect a disconnected sensor in some areas
without extensive running. For example, the “tray full” sensor has a
connector in the left cover and has to be disconnected to remove the
rear cover. The tray would have to be full for the sensor to function.
The sensor is also required for duplexing.
4-8 Service Manual
7001–001
Removal procedures
CAUTION: Be sure to unplug the power cord whenever you are
working on the MFP with one of the covers removed. Be sure to
remove the print cartridge before you perform removal procedures.
MFP cover removals
Front cover removal
1. Open the front cover.
2. Remove the four screws [A].
3. Remove the front cover.
A
Repair information 4-9
7001–001
Lower front cover (multipurpose feeder cover) removal
1. Open the front cover.
2. Open the MPF front cover to where the latches are clear
(about 15°).
3. Lift the left side of the cover to release it from the hinge.
4. Remove the lower front cover.
4-10 Service Manual
7001–001
Side cover removals
Left side cover removal
1. Open the front cover and the MPF cover.
2. Disengage the two latches (located in the front and top) [A].
A
3. Swing the left side cover away from the printer.
Repair information 4-11
7001–001
Note: With only the left side cover removed, the following items can
also now be removed and replaced:
• MPF gear–see “Multipurpose feeder (MPF)” on page 7-4 for
•
•
•
•
•
more information.
Toner level sensor–see “Electronics and cables” on page 7-8
for more information.
Motor with PWB–see “Paper feed” on page 7-14 for more
information.
Door latches–see “Frame” on page 7-16 for more information.
Paper feed solenoid–see “Electronics and cables” on
page 7-8 for more information.
RIP card cage cover–see “Electronics and cables” on
page 7-8 for more information.
– Memory–see “Options” on page 7-22 for more information.
– Connector cable for second drawer option–see “Electronics
and cables” on page 7-8 for more information.
– RIP card PCB–see “Electronics and cables” on page 7-8
for more information.
4-12 Service Manual
7001–001
Right side cover removal
1.Remove the paper tray.
2.Remove the right scanner pedestal cover. See
“Scanner right ADF cover removal” on
page 4-71 for more information.
3. Open the MPF.
4. Remove one screw [A].
A
Repair information 4-13
7001–001
5. While pulling out on the top of the right side cover, use your left
hand to release the two latches (top front [A] and lower front
[B]).
A
B
Note: The MPF door may need to be lifted slightly for the side
cover to clear.
6. Release the top rear latch, if necessary.
Swing the cover out and lift it from the base.
4-14 Service Manual
7001–001
Rear cover removal
1. Remove the paper tray.
2. Remove the right side cover. See “Right side cover removal”
on page 4-13 for more information.
3. Remove the left side cover. See “Left side cover removal” on
page 4-11 for more information.
4. Open the paper tray trim.
5. Open the exit tray (rear door).
6. Disconnect the sensor cable (inline connector) below the lower
left corner of the RIP card.
Note: Replug the sensor cable on reassembly. The MFP fails to
detect “tray full” and won’t duplex properly without this
connection.
Repair information 4-15
7001–001
7. Remove the four screws [A].
A
8. For better leverage, move the machine to the edge of the table.
Lift the top cover slightly with one hand while pulling out on the
rear cover.
Note: When reinstalling the rear cover, be sure to position the
fuser exit guide fingers such that they are not bound by the rear
cover. If a bind occurs, a jam occurs.
4-16 Service Manual
7001–001
Top cover assembly removal
1.Remove the scanner. See “Scanner assembly
removal” on page 4-79 for more information.
2.Remove the print cartridge.
3.Remove the four (4) screws in top cover [A]
A
4. Remove the four screws.
A
Repair information 4-17
7001–001
5. Remove the duct assembly in the top cover.
6. Carefully, lift the rear edge of the top cover to clear the exit flags
and rotate the front cover hinge until the cover is in a vertical
position.
4-18 Service Manual
7001–001
To completely remove the top cover:
7.Open the front cover.
8.Remove the E–clips from both hinges that
connect the charge roller and top cover [A].
A
9. Remove the stud hinges.
10. Remove the top.
The front cover remains attached to the top cover.
3–pin and 2–pin connectors removal
1. Remove the RIP card cage. See “RIP card cage (with card in
place) removal” on page 4-58 for more information.
2. Remove the rear cover. See “Rear cover removal” on
page 4-15 for more information.
3. Unplug the wires on both sides of the connectors.
4. Unsnap connectors and remove to the left side.
Repair information 4-19
7001–001
Bracket, opener shutter removal
1. Remove the HVPS. See “HVPS card removal” on page 4-39
for more information.
2. Remove the print cartridge.
3. Unsnap the latches from the frame.
4. Remove the opener shutter bracket.
Note: The bracket can be removed (with possible latch
breakage) by wedging a screwdriver or similar tool between the
bracket and the frame.
4-20 Service Manual
7001–001
Bracket, paper detect (input sensor) removal
1. Remove the print cartridge to expose latches in the bracket.
Leave the door open.
2. Remove the duplex tray assembly. See “Duplex tray assembly
removal” on page 4-29 for more information.
3. Disconnect the cable to the sensor or remove the sensor and
cable together.
4. Unlatch the bracket by pushing from inside the MFP and pulling
from the duplex side.
Repair information 4-21
7001–001
Cartridge coupling assembly removal
1. Remove the print cartridge.
2. Remove the top cover. See “Top cover assembly removal” on
page 4-17 for more information.
3. Remove the left cover. See “Left side cover removal” on
page 4-11 for more information.
4. Remove the RIP card cage. See “RIP card cage (with card in
place) removal” on page 4-58 for more information.
5. Remove the two screws [A].
A
6. Remove the bracket.
Note: The print cartridge coupling may need to be compressed
during removal.
4-22 Service Manual
7001–001
Charge roll removal
1. Open the front cover and remove the print cartridge.
2. Grasp the charge roll on the left end, and push the bearing and
roll away from each other.
Warning: Handle the charge roll with clean dry hands and only at
the ends.
3. After the left side is removed from the bearing, slide the roll from
the right side bearing.
Repair information 4-23
7001–001
Cooling fan removal
1. Remove the top cover. See “Top cover assembly removal” on
page 4-17 for more information.
2. Remove the right side cover. See “Right side cover removal”
on page 4-13 for more information.
3. Disconnect the fan cable.
4. Remove the two screws [A].
A
5. Remove the fan.
4-24 Service Manual
7001–001
D–roll tray 1 feed removal
1. Remove the left cover and inner cover for the MPF gearing. See
“Left side cover removal” on page 4-11 for more information.
2. Remove the duplex tray. See “Duplex tray assembly removal”
on page 4-29 for more information.
3. Disconnect extension spring [A] from the D–roll.
4. Release the latch on the paper feed solenoid. It is located
behind the lower right corner of the main drive assembly.
5. Rotate the main drive motor counterclockwise until the D–roll
clears the adjacent rib.
6. Using a slotted screwdriver as a wedge between the D–roll and
bearing wall, force the D–roll to unsnap from the shaft.
7. Slide the D–roll off the tray 1 feed shaft [B].
Repair information 4-25
7001–001
D–roll (tray 1) shaft assembly removal
1. Remove the left side cover. See “Left side cover removal” on
page 4-11 for more information.
2. Remove the inner cover.
3. Remove the MPF gear.
4. Remove the gear train assembly. See “Main drive assembly
removal” on page 4-44 for more information.
4-26 Service Manual
7001–001
5. Remove the solenoid [B].
6. With the MFP on its back, remove the D–roll.
Note: Slowly extract the shaft while facing the D–roll end.
Capture the small washer and the bearing. (The bearing must
be removed and reinserted through the opening adjacent to its
operating location [A]. See page 4-28 for more information.
Repair information 4-27
7001–001
Door latches (right side) removal
1. Remove the right side cover. See “Right side cover removal”
on page 4-13 for more information.
2. Remove the two screws [A] and replace the latches.
4-28 Service Manual
7001–001
Duplex tray assembly removal
1.
2.
3.
4.
5.
Remove the scanner document cover.
Remove the paper tray.
Disconnect all cables on the back of the printer.
Tilt the MFP on its back.
Remove the five screws [A].
A
A
6. Work the right side loose first and disconnect the paper input
sensor cable.
7. Remove the duplex assembly.
Repair information 4-29
7001–001
Fuser assembly, fuser paper exit guide,
Fuser exit sensor, and fuser lamp removal
3.
4.
5.
6.
7.
8.
1.Unplug the printer.
2.Remove the scanner assembly. See “Scanner
assembly removal” on page 4-79 for more
information.
Remove the top cover. See “Top cover assembly removal” on
page 4-17 for more information.
Remove the rear cover. See “Rear cover removal” on
page 4-15 for more information.
To remove the fuser assembly, release the two latches and
remove the cooling fan duct [A].
To replace only the paper exit guide or exit sensor, remove one
screw [B] to lift off the exit guide.
Disconnect the spring on the left side.
Swing out for clearance to replace.
A
4-30 Service Manual
B
7001–001
9. Unplug the exit sensor, and thermistor connector [A].
Note: It may be easier to unplug the fuser lamp once the fuser
is removed.
10. Remove the four screws [A].
Note: Removing the lower left screw requires a long
screwdriver (approximately a 6–inch shank).
Repair information 4-31
7001–001
11. While pulling the exit guide down, gently start pulling the fuser
towards you, unplugging the fuser lamp [A].
12. To replace the fuser lamp, remove the two screws [B] at each
end.
B
4-32 Service Manual
7001–001
13. Very carefully extract the lamp [A] from the heater roll
A
Warning: Do not touch the glass of a good lamp; it causes
premature failure.
Repair information 4-33
7001–001
Guide removals
Entrance guide removal
1. Remove the LSU (printhead). See “Printhead removal” on
page 4-54 for more information.
2. Remove the two screws [A] holding the entrance guide.
3. Remove the duplex unit. See “Duplex tray assembly
removal” on page 4-29 for more information.
4. Unsnap the two latches holding the entrance guide.
5. Remove the entrance guide.
6. Check the printhead alignment and adjust as necessary. See
“Printhead alignment adjustment” on page 4-2 for more
information.
4-34 Service Manual
7001–001
Left guide removal
1. Remove the print cartridge.
2. Remove the RIP card cage. See “RIP card cage (with card in
place) removal” on page 4-58 for more information.
3. Remove the charge roll. See “Charge roll removal” on
page 4-23 for more information.
4. Remove the three screws [A and B], one holding the link guide
bracket arm to the left guide.
5. Remove the left stud hinge on the top cover. See step 6 on
page 4-18 for more information.
6. Remove the HVPS. See “HVPS card removal” on page 4-39
for more information.
Repair information 4-35
7001–001
7. Disconnect the single conductor wire (spade connector) [A].
A
Note: Removal of the LSU (printhead) is not necessary but
gives better visibility and access. Illustrations are with the LSU
removed. See “Printhead removal” on page 4-54 for more
information.
8. Remove the wire from the retainers between the printers right
side and the left guide.
9. Unsnap the three latches [C] of the left guide while prying the
assembly from the frame.
10. Remove the left guide.
4-36 Service Manual
7001–001
Right guide removal
1. Remove the print cartridge.
2. Remove the HVPS. See “HVPS card removal” on page 4-39
for more information.
3. Remove the charge roll. See “Charge roll removal” on
page 4-23 for more information.
4. Remove two screws in the right guide (above and behind the
HVPS).
5. Remove the right stud hinge on the top cover. See “Top cover
assembly removal” on page 4-17 for more information.
6. Unsnap the three latches of the right guide.
7. Remove the right guide.
Repair information 4-37
7001–001
Paper guide roller removal
1. Remove the HVPS. See “HVPS card removal” on page 4-39
for more information.
2. Remove the print cartridge.
3. Remove the upper body MPF assembly. See “Upper (MPF)
housing assembly (with paper flag) removal” on page 4-66
for more information.
4. Unsnap the latch, which is part of the roller hub [A].
5. Remove the paper guide roller.
4-38 Service Manual
7001–001
HVPS card removal
1. Remove the top cover. See “Top cover assembly removal” on
page 4-17 for more information.
2. Remove the right side cover. See “Right side cover removal”
on page 4-13 for more information.
3. Disconnect the HVPS cable.
4. Remove the four screws [A].
A
5. Disconnect the charge roll cable.
6. Remove the HVPS card.
Repair information 4-39
7001–001
LVPS card removal
3.
4.
5.
6.
1.Unplug the printer.
2.Remove the top cover. See “Top cover
assembly removal” on page 4-17 for more
information.
Remove the right side cover. See “Right side cover removal”
on page 4-13 for more information.
Disconnect all cables attached to the LVPS card.
Remove the three screws [A].
Remove the LVPS [B].
A
4-40 Service Manual
B
7001–001
Lower (MPF) housing assembly removal
1. Remove the lower front MPF door. See “Lower front cover
(multipurpose feeder cover) removal” on page 4-10 for more
information.
2. Remove the left side cover. See “Left side cover removal” on
page 4-11 for more information.
3. Loosen the six screws in the RIP card cover.
Slide the cover toward the rear and remove.
4. Disconnect the MPF cable on the right side of the RIP card and
the toner level sensor.
5. Remove the three screws [A] on the front of the lower body
MPF assembly and gently remove the assembly.
Repair information 4-41
7001–001
Lower (MPF) housing assembly - paper sensor removal
1. Remove the lower front (MPF) door. See “Lower front cover
(multipurpose feeder cover) removal” on page 4-10 for more
information.
2. Remove the feed–roll cover, one screw.
3. At the lower–right assembly hinge, separate the metal plate
from the plastic housing.
4-42 Service Manual
7001–001
4. Support the left side with the left hand while separating the left
hinge.
Note: In the next step, note a loaded compression spring [A]
on the left side and under the metal plate.
A
5. Rotate the metal plate until the sensor can be accessed.
6. Disconnect the cable to the sensor and remove the sensor by
pushing on the latches underneath the sensor and housing.
7. Install the new sensor and reconnect the cable.
8. Reinstall the metal plate. Make sure the compression spring is
in the proper location and captured at its ends.
9. Rotate the metal plate to keep the spring positioned. Reconnect
the left hinge and then the right hinge.
Repair information 4-43
7001–001
Main drive assembly removal
1. Remove the top cover. See “Top cover assembly removal” on
page 4-17 for more information.
2. Remove the left side cover. See “Left side cover removal” on
page 4-11 for more information.
3. Remove the RIP card cage. See “RIP card cage (with card in
place) removal” on page 4-58 for more information.
4. Remove the inner cover, one (1) screw.
5. Remove the roller MPF gear by lifting the latch in the center of
the hub and sliding it out [D].
6. Free the cables from the attached retainers.
7. Remove the six (6) screws in the gear train assembly
[A, B, and C].
8. Lift up gently and work the gear train assembly out.
9. Remove the paper feed drive gear.
4-44 Service Manual
7001–001
Main drive motor assembly removal
1. Remove the left side cover. See “Side cover removals” on
page 4-11 for more information.
2. Disconnect the cable to the PWB.
3. Remove the four screws holding the metal base plate to the
gear train assembly.
4. Remove the motor assembly cover [A].
Repair information 4-45
7001–001
Motor assembly (stepper) removal
1. Remove the top cover. See “Top cover assembly removal” on
page 4-17 for more information.
2. Remove the left side cover. See “Left side cover removal” on
page 4-11 for more information.
3. Remove the RIP card cage. See “RIP card cage (with card in
place) removal” on page 4-58 for more information.
4. Remove three screws [B].
B
5. Lift the stepper motor out.
4-46 Service Manual
7001–001
MPF roller assembly removal
1. Remove the upper body MPF assembly. See “Upper (MPF)
housing assembly (with paper flag) removal” on page 4-66
for more information.
2. Remove the MPF cover. See “Lower front cover
(multipurpose feeder cover) removal” on page 4-10 for more
information.
3. Remove the left side and inner covers. See “Left side cover
removal” on page 4-11 for more information.
4. Remove the roller cover, one (1) screw. See “Lower (MPF)
housing assembly removal” on page 4-41 for more
information.
5. Remove the lower body MPF assembly. See “Lower (MPF)
housing assembly removal” on page 4-41 for more
information.
CAUTION:
– The lower body MPF assembly remains electrically
connected since it is not being replaced.
– Use care with the cable.
– Rotate the unit upside down to reduce stress on the cable.
Repair information 4-47
7001–001
6. Remove the MPF gear using your thumbnail to release the latch
and slide the gear from the shaft.
4-48 Service Manual
7001–001
7. Remove two screws [A] holding the roller assembly and one
screw facing the front of the printer.
8. Remove the roller assembly.
Repair information 4-49
7001–001
Operator panel removal
1. Release the four tabs under the SCU, below the operator panel.
2. Lift the front of the operator panel to release pivots in the rear.
4-50 Service Manual
7001–001
3. Disconnect the OPU-RIP cable.
A
4. Remove the operator panel.
Note: After replacing the operator panel, the customer’s settings
are lost and need to be reset.
• Perform scanner calibration and registration (See “Scanner
•
calibration” on page 4-5 and “MFP cover removals” on
page 4-9 for more information.)
Perform MFP registration (See “Printhead registration
adjustment” on page 4-4 for more information.)
Settings affected when the operator panel is replaced.
Setting
Menu where setting is found
Paper settings
Configuration menu
Printer settings
Configuration menu
Printer registration settings
Diagnostics menu
Defaults (US/Non US)
Diagnostics menu
Page count
Diagnostics menu
Permanent page count
Diagnostics menu
Serial number
Diagnostics menu
Repair information 4-51
7001–001
Setting
Menu where setting is found
Configuration ID
Diagnostics menu
Modem type
Diagnostics menu
Engine settings 1-4
Diagnostics menu
Edge to edge
Diagnostics menu
Error log
Diagnostics menu
Panel menus (enabled/disabled
Configuration menu
Energy conserve
Configuration menu
Paper prompts
Configuration menu
Envelope prompts
Configuration menu
Scanner registration settings
Configuration menu
Pick pad removal
1. Open the ADF center cover.
2. Remove the ADF pick roller.
3. Peel the old pick pad off the ADF feeder assembly.
4-52 Service Manual
7001–001
Replacement:
1. Place the long edge of the pick pad against the leading edge of
the pick pad guide on the ADF feeder assembly.
2. Press the pick pad firmly into the guide.
Note: To avoid jams, in the ADF, ensure the leading edge of the
pick pad is pressed firmly into the guide.
3. Replace the pick roller assembly.
4. Close the ADF center cover.
Repair information 4-53
7001–001
Printhead removal
1. Remove the top cover. See “Top cover assembly removal” on
page 4-17 for more information.
2. Disconnect the printhead cable [B].
3. Remove the four screws [A].
B
A
Note: Mark alignment of the printhead at the screw areas with
the printhead to keep the same alignment upon reinstallation.
4. Remove the printhead.
5. Check alignment of the printhead before reinstalling the top
cover. Adjust as necessary. See “Printhead alignment
adjustment” on page 4-2 for more information.
4-54 Service Manual
7001–001
Rear exit door removal
1. Open the rear exit door.
2. Use your index finger or screwdriver to disengage the left
(facing back of MFP) hinge from the rear cover. With your other
hand, apply force to remove the door from the MFP.
Repair information 4-55
7001–001
Reference plate assembly removal
1. Remove the print cartridge.
2. Remove the gear train assembly. See “Main drive assembly
removal” on page 4-44 for more information.
3. Remove the three screws located between the main gear drive
and the assembly plate.
4. Remove the MPF cover. See “Lower front cover
(multipurpose feeder cover) removal” on page 4-10 for more
information.
5. Remove the upper body MPF assembly. See “Upper (MPF)
housing assembly (with paper flag) removal” on page 4-66
for more information.
6. Remove the lower body MPF assembly. See “Lower (MPF)
housing assembly removal” on page 4-41 for more
information.
4-56 Service Manual
7001–001
7. Remove one screw in the cover adjacent to the assembly plate.
Notes:
– Remove the reference plate assembly through the front of
the MFP [A].
– When a reference plate (reference edge) assembly is
removed, reinstallation requires alignment. Use a long shank
(6–inch) Phillips screwdriver to adjust the rear screw holding
the assembly in place. It is accessed through the hole in the
main drive assembly between the RIP card cage and the
main motor PCB. Adjusting the screw counterclockwise
rotates paper counterclockwise in the MFP path.
Repair information 4-57
7001–001
RIP card cage (with card in place) removal
1. Remove the left side cover. See “Left side cover removal” on
page 4-11 for more information.
2. Loosen six screws [A] in the controller cage.
3. Slide the cage cover off.
4. Remove the top cover. See “Top cover assembly removal” on
page 4-17 for more information.
4-58 Service Manual
7001–001
5. Remove one screw from the drive assembly cover. Lift cover to
remove.
6. Disconnect all cables from the RIP card.
Note: The duplex connector must be fed through a chimney on
the card frame. Feed all cables through the cage frame.
Warning: When feeding cables through the RIP cage, take care not
to strip the insulation from the cables. This could result in a short.
7. Remove four screws from the RIP card [A].
8. Gently pull the bottom of the cage out and lift up off the two
posts at the top.
Repair information 4-59
7001–001
RIP card assembly removal
1. Remove the left side cover. See “Left side cover removal” on
page 4-11 for more information.
2. Loosen six screws [A] in the controller cage.
A
3. Slide the cage cover off.
4. Disconnect all cables from the RIP card.
Note: The duplex connector must be fed through a chimney on
the card cage frame. Feed all cables through the cage frame.
4-60 Service Manual
7001–001
5. Remove five screws [A] in the RIP card.
6. Remove one screw above the USB connector.
Repair information 4-61
7001–001
7.
Carefully, remove the RIP card.
Note: Perform the printhead and scanner calibration as well as the
scanner registration when replacing this part.
Setting
Menu where setting is found
Network settings
Administrative menu
General settings
Administrative menu
Copy settings
Administrative menu
Fax settings
Administrative menu
E-mail/FTP settings
Administrative menu
Security settings
Administrative menu
Set date and time settings
Administrative menu
PPDS mode
Configuration menu
Minimum copy memory
Configuration menu
ADF edge eraes value
Configuration menu
Flatbed edge erase value
Configuration menu
4-62 Service Manual
7001–001
Smart button sensor removal
1. Remove the print cartridge.
2. Remove the gear train assembly. See “Main drive assembly
removal” on page 4-44 for more information.
3. Remove the two screws and the bracket coupling assembly.
4. For additional clearance, remove the charge roll. See “Charge
roll removal” on page 4-23 for more information.
5. Remove the screw holding the smart button sensor [A].
6. Remove the two screws in the cable cover retainer.
7. Remove the sensor by pushing from inside the printer.
Note: Unplug the thermistor cable to remove the smart button
sensor.
Repair information 4-63
7001–001
Terminal assembly removal
1. Remove the HVPS. See “HVPS card removal” on page 4-39
for more information.
2. Remove the terminal assemblies [A].
A
Note: The lower right terminal (to the transfer roll) is gold in
color.
4-64 Service Manual
7001–001
Tray damper and spring removal
1. Remove the right side cover. See “Right side cover removal”
on page 4-13 for more information.
2. Remove the tray damper spring from the MFP frame post [A].
A
3. Rotate the lever counterclockwise as far as possible and lift out.
Repair information 4-65
7001–001
Transfer roll assembly and left transfer support bearing
removal
Note: Do not touch the transfer roll except on the ends.
1. Remove the print cartridge.
2. Unlatch and lift the left side support bearing.
3. Unlatch and lift the right transfer support bearing.
4. Remove the transfer roll.
Note: After reinstalling the transfer roll, use a thin screwdriver
to push the copper tab on the right side fully into the slot.
Upper (MPF) housing assembly (with paper flag)
removal
1. Open the front cover.
2. Remove two screws holding the assembly.
3. Carefully, lift the assembly out. A sensor flag is attached.
4-66 Service Manual
7001–001
Scanner cover removals
ADF upper cover removal
1. Remove the scanner document tray. See “Scanner document
tray assembly” on page 4-87 for more information.
2. Remove the flatbed cover. See “Flatbed cover removal” on
page 4-73 for more information.
3. Remove the right and left ADF covers. See “Scanner right
ADF cover removal” on page 4-71 and “Scanner left ADF
cover removal” on page 4-74 for more information.
4. Remove two screws [A].
A
A
5. Lift to remove the center ADF upper cover.
Repair information 4-67
7001–001
Scanner cover removal
Note: To replace the flatbed cover closed sensor, perform this
removal and replace the sensor with PN 56P0645. See
“Scanner sensors” on page 5-17 for more information.
1. Remove the scanner document tray. See -“Scanner document
tray assembly” on page 4-87 for more information.
2. Remove the flatbed cover. See “Flatbed cover removal” on
page 4-73 for more information.
3. Remove the right and left ADF covers. See “Scanner right
ADF cover removal” on page 4-71 and “Scanner left ADF
cover removal” on page 4-74 for more information.
4. Remove the ADF.
5. Remove three screws [A].
A
4-68 Service Manual
7001–001
6. Disconnect the document cover closed sensor connector.
A
7. With the operator panel removed. See “Operator panel
removal” on page 4-50 for more information.
Set off operator panel to expose the three tabs in the scanner
cover [A].
A
Repair information 4-69
7001–001
8. Release the three tabs.
9. Lift the scanner cover, and thread cable through chimney to
remove.
4-70 Service Manual
7001–001
Scanner right ADF cover removal
1. Remove the scanner document tray. See “Scanner document
tray assembly” on page 4-87 for more information.
2. Remove the flatbed cover. See “Flatbed cover removal” on
page 4-73 for more information.
3. Lift tab to release the ADF and pivot up to see under the left
cover.
4. Use a screwdriver to release 2 tabs [A].
A
A
Repair information 4-71
7001–001
5. Remove the right ADF cover.
4-72 Service Manual
7001–001
Flatbed cover removal
1. Remove the scanner document tray. See “Scanner document
tray assembly” on page 4-87 for more information.
2. Lift the flatbed cover to a vertical position.
3. Lift to extend the hinges, push to release the tab.
4. Remove the flatbed cover.
Repair information 4-73
7001–001
Scanner left ADF cover removal
1. Remove the document tray assembly. See “Scanner
document tray assembly” on page 4-87 for more information.
2. Remove the flatbed cover. See “Flatbed cover removal” on
page 4-73 for more information.
3. Lift the ADF cover to a vertical position.
4. Push with a screwdriver to release two tabs [A].
A
5. Remove the left ADF cover.
4-74 Service Manual
7001–001
Scanner ADF removal
1. Remove the document tray assembly. See “Scanner
document tray assembly” on page 4-87 for more information.
2. Remove the flatbed cover. See “Flatbed cover removal” on
page 4-73 for more information.
3. Remove the right, left, and upper ADF covers. See “Scanner
right ADF cover removal” on page 4-71, “Scanner left ADF
cover removal” on page 4-74, and “ADF upper cover
removal” on page 4-67 for more information.
4. Remove the left scanner cover.
5. Remove the ground screw in the SCU card [A].
6. Remove the following connectors on the SCU:
– ADF motor wiring harness (CN5) [B]
– ADF cover (CN8) [C]
– Paper position (SB1) [D]
A
B
D
C
Repair information 4-75
7001–001
7. Feed cables/connectors up through scanner unit.
8. Push the ADF [A] button to release the unit.
4-76 Service Manual
7001–001
9. Lift the ADF to remove.
Note: Perform the scanner calibration and scanner registration
procedures after replacing this part.
Repair information 4-77
7001–001
Scanner ADF motor removal
Note: This removal describes the removal of PN 56P2537 which is
part of PN 56P2252.
1. Remove the ADF assembly from the MFP.
2. Route the cables through the guides [A] so they clear the ADF
feeder assembly.
3. Remove the three screws [A] that fasten the ADF motor
assembly to the ADF feeder assembly.
4-78 Service Manual
7001–001
4. Carefully remove the ADF motor assembly from the ADF feder
assembly. Ensure the gears on the ADF assembly remain in the
uint.
Scanner assembly removal
1. Remove two screws on the back of the scanner [A].
A
Repair information 4-79
7001–001
2. From the rear of the scanner, slide the right scanner cover to the
rear to remove.
3. Remove two screws in the scanner base [A].
A
4. From the rear of the scanner, slide the left scanner cover to the
rear and remove.
4-80 Service Manual
7001–001
5. Remove two screws in the scanner base [A].
A
6. Remove MFP left side cover. See “Left side cover removal”
on page 4-11 for more information.
7. Remove the MFP RIP card cage cover. See “RIP card cage
(with card in place) removal” on page 4-58 for more
information.
8. Disconnect the following cables from the RIP card.
• SCU RIP harness [A]
• SCU power [B]
• SCU AFE [C]
• OPU-RIP cable [D]
Warning: When feeding cables through the RIP cage, take care not
to strip the insulation from the cables. This could result in a short.
Repair information 4-81
7001–001
9. Route the disconnected cables from the RIP card through the
chimneys to clear the printer.
10. From the rear of the machine, slide the scanner assembly
forward and lift assembly off the printer.
Scanner CCD carriage removal
1. Remove the document tray assembly. See “Scanner
document tray assembly” on page 4-87 for more information.
2. Remove the flatbed cover. See “Flatbed cover removal” on
page 4-73 for more information.
3. Remove the right and left ADF covers. See “Scanner right
ADF cover removal” on page 4-71 and “Scanner left ADF
cover removal” on page 4-74 for more information.
4. Remove the ADF. See “Scanner ADF removal” on page 4-75
for more information.
5. Remove the R2 and R1 idler. See “Scanner R2 idler removal”
on page 4-94 and “Scanner R1 idler removal” on page 4-92
for more information.
6. Remove the scanner cover. See “Scanner cover removal” on
page 4-68 for more information.
7. Disconnect the CCD-SCU ribbon cable from the SCU board,
and route the cable up through the scanner.
4-82 Service Manual
7001–001
8. Push the CCD carriage to the center of the scanner.
Warning: Do not touch the two lamps on top of the unit. This could
shorten the life of the lamps.
9. Lift the guide rod and remove it from the CCD carriage.
10. Pull timing belt off CCD.
Repair information 4-83
7001–001
11. Pull and slide the CCD off the timing belt.
12. Remove the CCD carriage.
Scanner CCD timing belt removal
1. Remove the document tray assembly. See “Scanner
document tray assembly” on page 4-87 for more information.
2. Remove the flatbed cover. See “Flatbed cover removal” on
page 4-73 for more information.
3. Remove the right and left ADF covers. See “Scanner right
ADF cover removal” on page 4-71 and “Scanner left ADF
cover removal” on page 4-74 for more information.
4. Remove the ADF. See “Scanner ADF removal” on page 4-75
for more information.
5. Remove the R2 and R1 idler. See “Scanner R2 idler removal”
on page 4-94 and “Scanner R1 idler removal” on page 4-92
for more information.
4-84 Service Manual
7001–001
6. Compress the spring on the idler roller [A]
A
7. Lift the timing belt off the gears to remove.
Repair information 4-85
7001–001
Scanner control unit card removal
Note: When replacing the SCU, make sure that the ADF motor
wiring harness is connected to CN5 on the SCU card and
that the flatbed motor wiring harness is connected to CN6. If
they are connected to the wrong connectors, the LCD on the
operator panel displays “Scanner locked, release lock under
scanner”.
1. Remove the left scanner base cover.
2. Disconnect all cables.
3. Remove four screws [A].
A
4. Remove the SCU card.
Note: Perform the scanner calibration and scanner registration
procedures after replacing this part.
4-86 Service Manual
7001–001
Scanner document tray assembly
1. Pull the document tray to the right to release.
2. Lift the document tray to remove.
Repair information 4-87
7001–001
Scanner flatbed motor assembly removal
1. Remove the scanner document tray. See “Scanner document
tray assembly” on page 4-87 for more information.
2. Remove the scanner document cover. See “Scanner cover
removal” on page 4-68 for more information.
3. Remove the right and left ADF covers. See “Scanner right
ADF cover removal” on page 4-71 and “Scanner left ADF
cover removal” on page 4-74 for more information.
4. Remove the ADF. See “Scanner ADF removal” on page 4-75
for more information.
5. Remove the R2 and R1 idler. See “Scanner R2 idler removal”
on page 4-94 and “Scanner R1 idler removal” on page 4-92
for more information.
6. Remove the scanner cover. See “Scanner cover removal” on
page 4-68 for more information.
7. Remove the CCD and CCD belt. See “Scanner CCD carriage
removal” on page 4-82 and “Scanner CCD timing belt
removal” on page 4-84 for more information.
8. Remove the flatbed ground screw.
9. Disconnect the flatbed motor.
4-88 Service Manual
7001–001
10. Route the cables up through the flatbed.
11. Remove two screws [A].
A
12. Lift to remove the flatbed motor.
Repair information 4-89
7001–001
13. Remove copper ground plate.
Note: This plate needs to be attached to the new flatbed motor.
4-90 Service Manual
7001–001
Scanner ADF pick roller assembly removal
1. Open ADF upper cover.
2. Hold the left connecting shaft on the ADF pick roller assembly.
3. Push the assembly toward the right side of the ADF until the
shaft is clear.
4. Lift and remove.
Repair information 4-91
7001–001
Scanner R1 idler removal
1. Remove the scanner document tray. See “Scanner document
tray assembly” on page 4-87 for more information.
2. Remove the flatbed cover. See “Flatbed cover removal” on
page 4-73 for more information.
3. Remove the right and left ADF covers. See “Scanner right
ADF cover removal” on page 4-71 and “Scanner left ADF
cover removal” on page 4-74 for more information.
4. Remove the ADF. See “Scanner ADF removal” on page 4-75
for more information.
5. Remove the R2 idler. See “Scanner R2 idler removal” on
page 4-94 for more information.
6. Remove four screws in the idler bracket.
A
7. Remove two screws.
8. Pull idler and bracket away from scanner and remove.
4-92 Service Manual
7001–001
9. Pull R1 idler down to release tabs on the underside of the
bracket. Slide out to remove.
Note: Reinstall: with R1 idler in bracket ensure the two teeth
[A] are inserted in notches.
A
Repair information 4-93
7001–001
Scanner R2 idler removal
1. Remove the scanner document tray. See “Scanner document
tray assembly” on page 4-87 for more information.
2. Remove the flatbed cover. See “Flatbed cover removal” on
page 4-73 for more information.
3. Remove the right and left ADF covers. See“Scanner right ADF
cover removal” on page 4-71 and “Scanner left ADF cover
removal” on page 4-74 for more information.
4. Remove the ADF. See “Scanner ADF removal” on page 4-75
for more information.
5. Remove two screws.
A
4-94 Service Manual
7001–001
6. Tilt the idler inward and lift to remove.
Note: Reinstall: ensure extended edge of the R2 idler [A] is
slipped under the scanner glass.
A
Repair information 4-95
7001–001
4-96 Service Manual
7001–001
5. Locations
Locations 5-1
7001–001
Cables
5-2 Service Manual
7001–001
Reference
Description
1
Cable Assembly, Cover Switch
2
Switch, Interlock Cover
3 and 4
Sensor and Cable included with P/N 56P0611
5 and 7
Solenoid, Paper Feed
6
Sensor, Toner Level
8
Cable Assembly, Drawer
9
Card Assembly, RIP
10
Cable Assembly, 3–pin Connector
11
Cable Assembly, 2–pin Connector
12
Sensor Cable, Output Full
13
Connector, 3–pin
14
Connector, 2–Pin
15
Sensor, Output Full
Locations 5-3
7001–001
Cables (continued)
8
7
6
5
11
10
5-4 Service Manual
9
1
3
4
2
7001–001
Reference
Description
1
Power Supply, 110 V
1
Power Supply, 220 V
2, 7, 8, 9
Cable Assembly, Main Harness
Locations:
2. HVPS
7. Fan
8. LVPS Power
9. LVPS Control
NS Paper–In, Duplex
3
Fuser PS, High Volt
4
Guide Assembly, Left
5
Cable Assembly, LVPS to Fuser
6
Fan, Cooling
10
Card Assembly, Network RIP, modem
11
Cable Assembly, Printhead
Locations 5-5
7001–001
Scanner cables
5-6 Service Manual
7001–001
Reference
Description
1
Cable assembly, SCU-flatbed motor
2
Sensor, photo
3
Cable assembly, SCU-ADF motor
4
Cable assembly, OPU-RIP
5
Cable assembly, SCU-CCD
6
Card, SCU
7
Card, RIP-NA (resistive)
7
Card, RIP-EU (reactive)
8
Cage, card
9
Cable assembly, SCU AFE-RIP
10
Cable assembly, power SCU-RIP
11
Cable assembly, SCU-RIP
Locations 5-7
7001–001
High voltage power supply (HVPS)
Function
name
Name on card
To RIP
J16–CN1
8
2
4
7
Charge
roll
C
Terminal
1
5-8 Service Manual
# of pins
Pin #
Signal
Gnd.
+24 V dc
+5 V dc
7001–001
Low voltage power supply (LVPS)
Function
name
Name on card
Control
CN1
4
1
Ground
To RIP
Card
CN2
12
1,2,3,7,8, 9
4,5,6
10,11,12
Ground
+5V
+24V
Heater
CN3
2
1-2
110/220 V
ac
On/Off
Switch
CN4
2
1-2
110/220 V
ac
# of pins
Pin #
Signal
Locations 5-9
7001–001
RIP card assembly
Note: Pin number 1 is designated on the printed
circuit card by either a white triangle, a number 1, or
both. The pin numbers follow chronologically to the
oppos
5-10 Service Manual
7001–001
Function
name
Name on card
# of pins
Pin #
Signal
Mirror
motor
J1–MMTR
5
4
5
Gnd.
+24 V
Cover open
J2–CO
3
1
2
3
+5 V closed
+5 V
Gnd.
LSU
J3–LSU
8
1, 5, 7
6
Gnd.
+5 V closed
10 pin
scanner
control
J4
10
3, 6, 9, 10,
Gnd.
30 pin SCU
AFE
J5
30
29, 30
Gnd.
Operator
panel
J6
32
1, 2, 15, 23,
24
6, 10, 16,
21, 22, 23,
31, 32
+5 V
Gnd.
MPF
solenoid
J11
2
Network
connector
J12F
Exit motor
J13
4
Main motor
J14
7
7
1, 6
+24 V
Gnd.
MPF toner
J17
6
1, 4
3, 6
+5 V
Gnd.
LVPS
control
J19
5
5
Gnd.
Modem
J20
FD
solenoid
J24
2
Locations 5-11
7001–001
RIP card assembly (continued)
Note: Pin number 1 is designated on the printed
circuit card by either a white triangle, a number 1, or
both. The pin numbers follow chronologically to the
oppos
5-12 Service Manual
7001–001
Function
name
Name on card
# of pins
Pin #
Signal
Tray 2
J25
6
6
4
5
+24 V
+5 V
Gnd.
Exit, rear
cover
sensors
J27
6
1, 4
3, 6
+5 V
Gnd.
LVPS DC
power
J28
10
1, 2, 10
3, 4, 9
5, 7
+24 V
Gnd.
+5 V
Thermistor,
smart IC
J29
5
2, 5
Gnd.
HVPS, fan,
fan ground
J30
11
10
7
5
+5 V
+24 V
Gnd.
Paper
input,
narrow
media,
duplex
J31
9
1, 4, 7
3, 6, 9
+5 V
Gnd.
Power to
SCU
J32
4
1
2, 3
4
+5 V
Gnd.
+24 V
USB
J37
G1, G2
1
Gnd.
USB power
Locations 5-13
7001–001
SCU connectors
5-14 Service Manual
7001–001
Function
name
Name on card
# of pins
Pin #
Signal
Scanner
Control
CN2
10
From RIP
SCU AFE
CN3
30
CCD
CN4
22
16, 17
2, 22
+12 V
Ribbon cable
connector
ADF
connect
or
CN5
6
1, 2
+24V
Flat Bed
Motor
CN6
6
2, 5
+24V
Power
from RIP
CN7
4
1
4
+5V
+24V
Sensors
in ADF
(Cover
Closed
and
Paper
Position)
CN8
6
SB 1
(Paper
Present
Sensor)
CN9
3
Flatbed
Cover
Open
CN10
3
Locations 5-15
7001–001
Sensors
8
1
7
6
5
4
3
2
Reference
Description
1
Paper Path Exit Flag
2
Paper Path below Cartridge
3
Paper Path Duplex
4
Paper Path MPF
5
Paper Path below Cartridge
6
Sensor, Toner Level
7
Sensor, Smart Button
8
Sensor, Fuser Exit
5-16 Service Manual
7001–001
Scanner sensors
Reference
Description
1
Paper present sensor
2
Paper position sensor
3
ADF cover closed sensor
4
Flatbed cover closed sensor
Note: Sensors 1-3 are only available as part of the ADF assembly.
Locations 5-17
7001–001
5-18 Service Manual
7001–001
6. Preventive maintenance
This chapter describes procedures for MFP preventive maintenance.
Following these recommendations can help prevent problems and
maintain optimum performance.
Lubrication specifications
Lubricate only when parts are replaced or as needed, not on a
scheduled basis. Use of lubricants other than those specified can
cause premature failure. Some unauthorized lubricants may
chemically attack polycarbonate parts. Use IBM no. 10 oil,
P/N 1280443 (approved equivalents: Mobil DTE27, Shell Tellus 100,
Fuchs Renolin MR30), IBM no. 23 grease (approved equivalent:
Shell Darina 1), and grease, P/N 99A0394 to lubricate appropriate
areas of the printer.
Safety inspection guide
This inspection guide aids you in identifying unsafe conditions.
If any unsafe conditions exist, find out how serious the hazard could
be and if you can continue before you correct the hazard.
Check the following items:
• Damaged, missing, or altered parts, especially in the area of the
•
•
on/off switch and the power supply.
Damaged, missing, or altered covers, especially in the area of
the top cover and the power supply cover.
Possible safety exposure from any non–Lexmark attachments.
Preventive maintenance 6-1
7001–001
6-2 Service Manual
7001-001
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.
AR: (As Required) in the Units column indicates that the
quantity is not the same for all machines.
NS: (Not Shown) in the Asm-Index column indicates that the
part is procurable but is not pictured in the illustration.
PP: (Parts Packet) in the parts description column indicates the
part is contained in a parts packet.
Parts catalog 7-1
7001-001
Assembly 1: Covers
7-2 Service Manual
7001-001
Assembly 1: Covers
AsmIndex
Part
Numbers
Units
1–1
56P2508
1
Cover assembly, rear
2
56P0607
1
Door assembly, rear exit
3
56P0680
1
Flap, paper holder
4
56P0603
1
Cover assembly, duct
5
56P2258
1
Cover assembly, top
6
56P2257
1
Cover assembly, right
7
56P2265
1
Cover assembly, front with display
(with logo)
Description
8
56P0610
1
Cover assembly, MPF door
10
56P0600
1
Cover assembly, left
Parts catalog 7-3
7001-001
Assembly 2: Multipurpose feeder (MPF)
5
1
4
2
3
7-4 Service Manual
7001-001
Assembly 2: Multipurpose feeder (MPF)
AsmIndex
Part
Numbers
Units
Description
2–1
56P0612
1
Housing assembly, upper (MPF)
2
56P0611
1
Housing assembly, lower (MPF)
3
56P0615
1
Cap, MPF paper feed cover
4
56P2181
1
Assembly, roller (MPF)
5
56P0614
1
Gear, MPF paper pick
Parts catalog 7-5
7001-001
Assembly 3: Charging
3
2
1
2
7
3
5
4
6
7-6 Service Manual
7001-001
Assembly 3: Charging
AsmIndex
Part
Numbers
Units
Description
3–1
56P0640
1
Roll, charge
2
56P0668
1
Parts pack, (screws and E–rings)
3
56P0669
1
Hinge, pivot (quantity 2)
4
56P0642
1
Guide assembly, right
5
56P0643
1
Assembly, transfer roll
6
56P0644
1
Bearings, transfer roll
7
56P0641
1
Guide assembly, left
Parts catalog 7-7
7001-001
Assembly 4: Electronics and cables
8
7
6
5
11
10
7-8 Service Manual
9
1
3
4
2
7001-001
Assembly 4: Electronics and cables
AsmIndex
Part
Numbers
Units
4–1
56P2285
1
Power supply, 110 V
1
56P2284
1
Power supply, 220 V
2, 7, 8, 9
56P2273
1
Cable assembly, main harness
Description
Locations:
2. HVPS
7. Fan
8. LVPS Power
9. LVPS Control
NS Paper–In, Duplex
3
56P0628
1
PS, high volt
4
56P0641
1
Guide assembly, left
5
56P0650
1
Cable assembly, LVPS to fuser
6
56P0630
1
Fan, cooling
10
56P2734
1
Card, RIP—NA (resistive)
10
56P2735
1
Card, RIP—EU (reactive)
11
56P0622
1
Cable assembly, printhead
Reactive
Australia, Austria, Belgium, Bulgaria, Denmark,
Finland, France, Germany, Greece, Iceland, Ireland,
Israel, Italy, Luxembourg, Netherlands, New Zealand,
Norway, Portugal, Russia, Senegal, south Africa,
Spain, Sweden, Switzerland, Turkey, UK
Resistive
US, Argentina, Brazil (HV), Brazil (LV), Canada, Chile,
Colombia, Costa Rica, Dominican Republic, El
Salvador, Equador, Guam, Guatemala, Honduras,
Hong Kong, Malaysia, Mexico, Nicaragua, Panama,
Paraguay, Peru, Poland, Puerto Rico, Singapore,
Venezuela, Virgin Islands
Parts catalog 7-9
7001-001
Assembly 4 (cont.): Electronics and cables
7-10 Service Manual
7001-001
Assembly 4 (cont.): Electronics and cables
AsmIndex
Part
Numbers
1
56P0624
1
Cable assembly, cover switch
2
56P0625
1
Switch, interlock cover
Units
3 and 4
Description
Sensor and Cable included with
P/N 56P0611 (lower MPF housing)
5 and 7
56P0616
2
Solenoid, paper feed
6
56P0653
1
Sensor, toner level
8
56P0631
1
Cable assembly, drawer
9
56P2734
1
Card, RIP—NA (resistive) (See
page 7-9 for more information.))
9
56P2735
1
Card, RIP—EU (reactive) (See
page 7-9 for more information.)
10
56P0664
1
Cable assembly, output full (and
fuser exit)
11
56P0652
1
Sensor, smart button
12
56P0682
1
Sensor cable, output full
13
56P0665
1
Connector, 3–pin
14
56P0666
1
Connector, 2–pin
15
56P0645
1
Sensor, photo
NS
56P0649
1
Cable assembly, fuser exit
NS
56P0620
1
Cable assembly, motor
Parts catalog 7-11
7001-001
Assembly 4 (cont.): Electronics and cables
This page left intentionally blank.
7-12 Service Manual
7001-001
Assembly 4 (cont.): Electronics and cables
AsmIndex
Part
Numbers
Units
NS
70G0478
1
Power cord, Bolivia, Canada,
Caribbean Countries, Columbia,
Costa Rica, Dominican Republic,
Equador, El Salvador, Guatemala,
Honduras, Japan, Mexico,
Nicaragua, Peru, Panama, Puerto
Rico, Saudi Arabia, Taiwan, The
Virgin Islands, Venezuela, US,
AP–LV
NS
1339528
1
Power cord, Bahrein, Cyprus, Iraq,
Ireland, Kuwait, Oman, Qatar, UAE,
UK, Yemen, (HV)
NS
1339529
1
Power cord, Austria, Belgium,
Bosnia, Bulgaria, Catalan, Czech,
Croatia, Egypt, Albania (Euro
English and other East), Finland,
France, Germany, Greece, Hungary,
Iceland, Iran, Italy, Jordan,
Lebanon, Macedonia, Netherlands,
Norway, Paraguay, Poland,
Portugal, Romania, Russia, and
CIS, Slovak Countries, Slovenia,
Spain, Sweden, Syria, Turkey,
Yugoslavia (Serbia and
Montenegro)(HV)
NS
1339530
1
Power cord, Israel (HV)
NS
1339531
1
Power cord, Switzerland (HV)
NS
1339532
1
Power cord, Libya, Pakistan, South
Africa (HV)
NS
1339533
1
Power cord, Chile, Uruguay (HV)
Description
NS
1339534
1
Power cord, Denmark (HV)
NS
43H5545
1
Power cord, PR China (HV)
NS
1339548
1
Power cord, Brazil (LV)
NS
11D0330
1
Power cord, Argentina
NS
1339520
1
Power cord, U.S. (HV) RPQ
Parts catalog 7-13
7001-001
Assembly 5: Paper feed
17
16
15
1
14
13
12
11
10
9
6
2
8
5
7
4
7-14 Service Manual
3
7001-001
Assembly 5: Paper feed
AsmIndex
Part
Numbers
Units
5–1
56P0677
1
Flags, stack control
2
56P0651
1
Assembly, duplex
3
56P0645
1
Sensor, photo
4
56P0618
1
Spring, D–roll
5
56P0656
1
Roll, paper feed
6
56P0655
1
Bracket, paper sensor
7
56P0657
1
Assembly, paper feed
8
56P0654
1
Plate assembly
Description
9
56P0634
1
Gear, paper feed
10
56P0693
1
Roller asm., reference backup (top
front and rear)
11*
56P0633
1
Assembly, drive
12
56P0632
1
Motor assembly, main drive
13
56P0638
1
Coupling, cartridge
14*
56P0637
1
Drive, ratchet
15*
56P0635
1
Assembly, motor
16*
56P0636
1
Gears, spur
17
56P0639
1
Guide, link
Parts catalog 7-15
7001-001
Assembly 6: Frame
1
2
8
3
4
11
4
10
9
4
8
5
4
12
7-16 Service Manual
7
6
7001-001
Assembly 6: Frame
AsmIndex
Part
Numbers
Units
6–1
56P0606
1
Duct, air
2
56P0623
1
Assembly, printhead
3
56P0629
1
Assembly, cartridge contacts
(quantity 5)
Description
4
56P0662
1
Feet, base
5
56P0661
1
Damper, tray
6
56P0668
1
Parts pack, (screws and E–rings)
7
56P0609
1
Assembly, tray 1
8
56P0667
1
Latch, door (3 latches)
9
56P0660
1
Roller, paper guide
10
56P0659
1
Bracket, shutter
11
56P0672
1
Bracket, body–tray
12
56P0658
1
Guide, entrance
* Order a lubricant to use with these gears, P/N 99A0394, (FRU,
Nyogel 744). See page 4-6 for more information.
Parts catalog 7-17
7001-001
Assembly 7: Fuser
1
2
3
4
7-18 Service Manual
7001-001
Assembly 7: Fuser
AsmIndex
Part
Numbers
Units
7–1
56P0648
1
Assembly, fuser (110 V)
1
56P0671
1
Assembly, fuser (220 V)
2
56P0673
1
Fuser assembly, paper guide
3
56P0676
1
Spring, fuser exit
4
56P0646
1
Lamp, fuser (110 V)
4
56P0647
1
Lamp, fuser (220 V)
Description
Parts catalog 7-19
7001-001
Assembly 8: Sensors
8
1
7
6
5
4
7-20 Service Manual
3
2
7001-001
Assembly 8: Sensors and locations
AsmIndex
Part
Numbers
Units
8 1–5, 8
56P0645
1
Description
Sensor, photo
Locations:
1. Paper path exit flag
2. Narrow media
3. Paper path duplex
4. Paper path MPF
5. Paper path below cartridge
8. Fuser exit sensor
2, 5
56P0655
1
Bracket, paper sensor
6
56P0653
1
Sensor, toner level
7
56P0652
1
Sensor, smart button
Parts catalog 7-21
7001-001
Assembly 9: Options
1
2
3
4
7-22 Service Manual
7001-001
Assembly 9: Options
AsmIndex
Part
Numbers
Units
Description
9–1
56P0674
1
Drawer assembly, 250–sheet
2
56P0609
1
Tray, 250–sheet
2
56P0681
1
Tray, 250–sheet label
3
56P0675
1
Drawer assembly, 500–sheet
4
56P0678
1
Tray, 500–sheet
NS
56P0694
1
DIMM, 4MB SDRAM
NS
56P0695
1
DIMM, 8MB SDRAM
NS
56P0696
1
DIMM, 16MB SDRAM
NS
56P0697
1
DIMM, 32MB SDRAM
NS
56P0698
1
DIMM, 64MB SDRAM
NS
56P0699
1
DIMM, 128MB SDRAM
NS
99A1757
1
DIMM, 2MB flash
NS
99A1758
1
DIMM, 4MB flash
NS
99A1759
1
DIMM, 8MB flash
NS
99A1774
1
DIMM, 16MB flash
NS
56P1418
1
DIMM, 32MB flash
NS
99A1683
1
DIMM, Optra Forms™ 2MB flash
NS
99A1684
1
DIMM, Optra Forms 4MB flash
NS
99A1685
1
DIMM, Optra Forms 8MB flash
NS
99A1686
1
DIMM, Optra Forms 16MB flash
NS
56P1427
1
DIMM, Optra Forms 32MB flash
NS
56P1248
1
DIMM, Japanese 8MB font
NS
56P1250
1
DIMM, Simplified Chinese font
NS
56P1251
1
DIMM, Traditional Chinese font
NS
56P2231
1
DIMM, Korean font
NS
12G9833
1
MarkNet™ X2011e Ethernet 10/100
BaseTX
Parts catalog 7-23
7001-001
Assembly 9 (cont.): Options
1
2
3
4
7-24 Service Manual
7001-001
Assembly 9 (cont.): Options
AsmIndex
Part
Numbers
Units
Description
NS
12G9832
1
MarkNet X2012e Ethernet 10/100
BaseTX/10Base2
NS
12G9831
1
MarkNet X2031e Ethernet 10/100
BaseTX
NS
12G9830
1
MarkNet X2030t Token–Ring
NS
99A0545
1
Adapter, external serial
NS
1329605
1
Cable, high–speed bidirectional
parallel (10 ft)
NS
1427498
1
Cable, high–speed bidirectional
parallel (20 ft)
NS
12A2405
1
Cable, USB 2–meter
NS
1038693
1
Cable, serial (50 ft)
NS
7370971
1
Kit, field relocation
Parts catalog 7-25
7001-001
Assembly 10: Scanner base
1
9
10
2
3
8
7
4
6
7-26 Service Manual
5
7001-001
Assembly 10: Scanner base
AsmIndex
Part
Numbers
10-1
56P2269
1
Belt, timing
2
56P2278
1
Cable, CCD-SCU
3
56P2272
1
Motor assembly, flatbed with cable
4
56P2267
1
Cover, right scanner
5
56P2261
1
Panel, operator
6
56P2286
1
Overlay, operator panel (FIGSD)
6
56P2287
1
Overlay, operator panel (DNSFBP)
7
56P2276
1
Cable, OPU-RIP
8
56P2268
1
Cover, left scanner
9
56P2271
1
Card, SCU
10
56P2270
1
Carriage, CCD
Units
Description
Parts catalog 7-27
7001-001
Assembly 11: Scanner top
7-28 Service Manual
7001-001
Assembly 11: Scanner top
AsmIndex
Part
Numbers
Units
11-1
56P2266
1
Cushion, scan cover
2
56P2263
1
Tray assembly, document
3
56P2264
1
Cover, flatbed
4
56P2262
1
Cover, scanner
5
56P2251
1
Idler, R2
6
56P2260
1
Cover, ADF left
7
56P2250
1
Idler, R1
8
56P2649
1
Roller kit, ADF pick and separator
Description
9
56P2252
1
Feeder assembly, auto document
10
56P2255
1
Pad, pick
11
56P2254
1
Cover, separator
12
56P2259
1
Cover, ADF right
13
56P2256
1
Cover, ADF upper
Parts catalog 7-29
7001-001
Assembly 12: Scanner cables
7-30 Service Manual
7001-001
Assembly 12: Scanner cables
AsmIndex
Part
Numbers
Units
5–1
56P2272
1
Motor assembly, flatbed with cable
2
56P0645
1
Sensor, photo
3
56P2539
1
Motor assembly, ADF with cable to
SCU
4
56P2276
1
Cable assembly, OPU-RIP
5
56P2278
1
Cable assembly, SCU-CCD
6
56P2271
1
Card, SCU
7
56P2734
1
Card, RIP—NA (resistive) (See
page 7-9 for more information.)
7
56P2735
1
Card, RIP—EU (reactive) (See
page 7-9 for more information.)
8
56P2283
1
Cage, card
Description
9
56P2277
1
Cable assembly, SCU AFE-RIP
10
56P2517
1
Cable assembly, power SCU-RIP
11
56P2275
1
Cable assembly, SCU-RIP
Parts catalog 7-31
7001-001
7-32 Service Manual
7001–001
Index
A
H
acronyms 1-15
adjusting paper feed alignment 4-2
adjustments 4-2
paper feed alignment 4-2
printhead assembly 4-2
handling ESD-sensitive parts 4-1
HVPS card removal 4-39
L
entrance guide removal 4-34
ESD-sensitive parts 4-1
laser notices 1-vii
left guide removal 4-35
left side cover removal 4-11
left transfer support bearing removal
4-66
locations 5-1
cables 5-2
cables (continued) 5-4
front 5-1
HVPS 5-8
LVPS 5-9
RIP card assembly 5-10
RIP card assembly (continued)
5-12
scanner cables 5-6
scanner sensors 5-17
SCU connectors 5-14
sensors 5-16
side 5-1
lower (MPF) housing assembly - paper
sensor removal 4-42
lower (MPF) housing assembly
removal 4-41
lower front cover removal 4-10
lubrication 4-6
lubrication specifications 6-1
LVPS card removal 4-40
F
M
flash memory 1-4
fonts 1-3
front cover removal 4-9
fuser assembly removal 4-30
fuser exit sensor removal 4-30
fuser lamp removal 4-30
fuser paper exit guide removal 4-30
main drive assembly removal 4-44
main drive motor assembly removal
4-45
maintenance approach 1-1
memory 1-4
flash memory 1-4
MFP features
connectivity 1-3
B
bracket, opener shutter removal 4-20
bracket, paper detect (input sensor)
removal 4-21
C
cartridge coupling assembly removal
4-22
connectivity 1-3
connector removals - 3-pin and 2-pin
4-19
cooling fan removal 4-24
D
data streams 1-7
diagnostic information 2-1
door latches (right side) removal 4-28
D-roll (Tray 1) shaft assembly removal
4-26
duplex tray assembly removal 4-29
E
I-1
7001–001
data streams 1-7
fonts 1-3
media 1-6
textures 1-6
weights 1-6
memory 1-4
operator panel 1-5
paper handling 1-8
print area 1-5
print quality 1-10
resolution 1-10
RIP card specifications 1-11
speed 1-9
supplies 1-11
user flash memory 1-4
MFP identification 1-2
MFP speed 1-9
MFP symptom table 2-8
motor assembly (stepper) removal
4-46
MPF roller assembly removal 4-47
O
operator panel
diagnostics 2-4
service checks 2-32
P
paper guide roller removal 4-38
paper handling 1-8
options 1-8
paper jam secondary lights 2-2
part number index 1-1
parts catalog 7-1
cables 7-10
charging 7-6
covers 7-2
electronics 7-8
frame 7-16
fuser 7-18
how to use 7-1
multipurpose feeder (MPF) 7-4
options 7-22
paper feed 7-14
scanner base 7-26
scanner cables 7-30
I-2 Service Manual
scanner top 7-28
sensors 7-20
POST symptom table 2-7
Power-on self test (POST) 2-5
preventive maintenance 6-1
print area 1-5
print media 1-6
textures 1-6
weights 1-6
print quality 1-10
solving problems 2-49
using test pages 2-49
printhead alignment adjustment 4-2
R
rear cover removal 4-15
rear exit door removal 4-55
reassembly note 4-8
reference plate assembly removal
4-56
removals 4-9
bracket, opener shutter 4-20
bracket, paper detect 4-21
card
HVPS 4-39
LVPS 4-40
RIP card 4-60
RIP card and cage 4-58
cartridge coupling assembly 4-22
charge roll 4-23
connectors
2-pin 4-19
3-pin 4-19
cooling fan 4-24
cover
front 4-9
left side 4-11
lower front 4-9
MPF 4-10
rear 4-15
right side 4-13
top 4-19
top cover assembly 4-17
door latches (right side) 4-28
D-roll
tray 1 feed 4-25
7001–001
tray 1 shaft assembly 4-26
duplex tray assembly 4-29
fuser assembly 4-30
fuser exit sensor 4-30
fuser lamp 4-30
fuser paper exit guide 4-30
guide
entrance 4-34
left 4-35
right 4-37
lower MPF assembly 4-41
main drive assembly 4-44
motors
main drive assembly 4-45
stepper 4-46
MPF roller assembly 4-47
paper guide roller 4-38
printhead 4-54
rear exit door 4-55
reference plate assembly 4-56
scanner ADF 4-75
scanner ADF motor 4-78
scanner ADF pick roller assembly
4-91
scanner assembly 4-79
scanner CCD carriage 4-82
scanner CCD timing belt 4-84
scanner control unit card 4-86
scanner covers 4-67
ADF upper 4-67
flatbed 4-73
left ADF 4-74
right ADF 4-71
scanner 4-68
scanner document tray assembly
4-87
scanner flatbed motor assembly
4-88
scanner R1 idler 4-92
scanner R2 idler 4-94
sensor
MPF - paper sensor 4-42
smart button 4-63
terminal assembly 4-64
transfer roll assembly
left transfer bearing 4-66
tray damper 4-65
spring 4-65
upper MPF assembly 4-66
resolution 1-10
right guide removal 4-37
right side cover removal 4-13
RIP card assembly removal 4-60
RIP card cage removal 4-58
RIP card specifications 1-11
roll tray 1 feed removal 4-25
S
safety information 1-xvii
safety inspection guide 6-1
scanner ADF motor removal 4-78
scanner ADF pick roller assembly
removal 4-91
scanner ADF removal 4-75
scanner ADF upper cover removal
4-67
scanner assembly removal 4-79
scanner CCD carriage removal 4-82
scanner CCD timing belt removal
4-84
scanner control unit card removal
4-86
scanner cover removal 4-68
scanner document tray assembly
removal 4-87
scanner flatbed cover removal 4-73
scanner flatbed motor assembly
removal 4-88
scanner left ADF cover removal 4-74
scanner right ADF cover removal
4-71
scanner R1 idler removal 4-92
scanner R2 idler removal 4-94
serial number 1-14
service checks
ADF 2-19
cooling fan 2-20
cover interlock switch 2-21
dead machine 2-22
E-mail 2-23
fuser 2-25
cold fuser 2-26
hot fuser 2-28
I-3
7001–001
HVPS/cartridge 2-29
LVPS power supply 2-24
main motor 2-30
network printing 2-31
operator panel 2-32
paper feed 2-33, 2-34, 2-35,
2-36, 2-37, 2-38
print quality 2-39
bands 2-45
black lines 2-45
black page 2-41
heavy background 2-42
light print 2-44
partial blank image 2-43
poor fusing of image 2-44
toner on back of page 2-45
variation 2-43
white lines 2-45
white spots 2-43
RIP card 2-46
scanner/copier 2-47
transfer roll 2-48
USB 2-48
service error codes 2-13
900 - RIP software error 2-13
902 - engine software error 2-13
920 - fuser error 2-13
921 - fuser error 2-13
922 - fuser error 2-13
923 - fuser error 2-13
924 - fuser error 2-13
925 - fuser error 2-13
929 - toner sensor 2-13
931 - printhead error 2-14
932 - printhead error 2-14
935 - printhead error 2-14
936 - transport motor 2-14
937 - transport motor 2-14
939 - RIP engine communications
2-14
940 - LVPS 2-14
941 - image pipeline 2-15
942 - scanner failure 2-15
943 - scanner failure 2-15
944 - scanner failure 2-15
945 - scanner failure 2-15
946 - scanner failure 2-15
I-4 Service Manual
947 - modem failure 2-16
948 - fax storage 2-16
949 - fax storage 2-16
952 - NV failure 2-16
953 - NVRAM failure 2-16
954 - NVRAM failure 2-16
955 - code CRC 2-16
956 - system board 2-16
957 - system board 2-16
958 - NAND failure 2-16
959 - system board 2-16
960 - memory error 2-16
961 - memory error 2-16
962 - memory error 2-17
965 - panel failure 2-17
976 - standard network 2-17
smart button sensor removal 4-63
special tools 1-14
supplies 1-11
symptom tables 2-6
MFP 2-8
POST 2-7
T
terminal assembly removal 4-64
top cover assembly removal 4-17
transfer roll assembly removal 4-66
tray damper and spring removal 4-65
U
upper (MPF) housing assembly
removal 4-66
7001-001
Part number index
P/N
Description
Page
1038693
11D0330
12A2405
12G9830
12G9831
12G9832
12G9833
1329605
1339520
1339528
1339529
1339530
1339531
1339532
1339533
1339534
1339548
1427498
43H5545
56P0600
56P0603
56P0606
56P0607
56P0609
56P0609
56P0610
56P0611
56P0611
56P0611
56P0612
56P0614
56P0615
56P0616
56P0618
56P0620
56P0622
56P0623
56P0624
56P0625
Cable, serial (50 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Power cord, Argentina . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Cable, USB 2-meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
MarkNet X2030t Token-Ring . . . . . . . . . . . . . . . . . . . . . . . . 7-25
MarkNet X2031e Ethernet 10/100 BaseTX . . . . . . . . . . . . . 7-25
MarkNet X2012e Ethernet 10/100 BaseTX/10Base2 . . . . . . 7-25
MarkNet X2011e Ethernet 10/100 BaseTX . . . . . . . . . . . . . 7-23
Cable, high-speed bidirectional parallel (10 ft) . . . . . . . . . . . 7-25
Power cord, U.S. (HV) RPQ . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Power cord - see listing in parts catalog . . . . . . . . . . . . . . . . 7-13
Power cord - see listing in parts catalog . . . . . . . . . . . . . . . . 7-13
Power cord, Israel (HV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Power cord, Switzerland (HV) . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Power cord, Libya, Pakistan, South Africa (HV) . . . . . . . . . . 7-13
Power cord, Chile, Uruguay (HV) . . . . . . . . . . . . . . . . . . . . . 7-13
Power cord, Denmark (HV) . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Power cord, Brazil (LV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Cable, high-speed bidirectional parallel (20 ft) . . . . . . . . . . . 7-25
Power cord, PR China (HV) . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Cover assembly, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Cover assembly, duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Duct, air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Door assembly, rear exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Assembly, tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Tray, 250-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Cover assembly, MPF door . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Housing assembly, lower (MPF) . . . . . . . . . . . . . . . . . . . . . . . 7-5
Sensor and cable included with . . . . . . . . . . . . . . . . . . . . . . 7-11
Sensor and Cable Included with P/N 56P0611 . . . . . . . . . . . . 5-3
Housing assembly, upper (MPF) . . . . . . . . . . . . . . . . . . . . . . 7-5
Gear, MPF paper pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Cap, MPF paper feed cover . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Solenoid, paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Spring, D-roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Cable assembly, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Cable assembly, printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Assembly, printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Cable assembly, cover switch . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Switch, interlock cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
I-5
7001-001
56P0628
56P0629
56P0630
56P0631
56P0632
56P0633
56P0634
56P0635
56P0636
56P0637
56P0638
56P0639
56P0640
56P0641
56P0642
56P0643
56P0644
56P0645
56P0646
56P0647
56P0648
56P0649
56P0650
56P0651
56P0652
56P0653
56P0654
56P0655
56P0656
56P0657
56P0658
56P0659
56P0660
56P0661
56P0662
56P0664
56P0665
56P0666
56P0667
56P0668
56P0669
56P0671
56P0672
56P0673
56P0674
PS, high volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Assembly, cartridge contacts (quantity 5) . . . . . . . . . . . . . . . . 7-17
Fan, cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Cable assembly, drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Motor assembly, main drive . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Assembly, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7, 7-15
Gear, paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Assembly, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8, 7-15
Gears, spur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8, 7-15
Drive, ratchet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7, 7-15
Coupling, cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Guide, link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Roll, charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Guide assembly, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7, 7-9
Guide assembly, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Assembly, transfer roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Bearings, transfer roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Sensor, photo . . . . . . . . . . . . . . . . . . . . . . . 7-11, 7-15, 7-21, 7-31
Lamp, fuser (110 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Lamp, fuser (220 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Assembly, fuser (110 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Cable assembly, fuser exit . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Cable assembly, LVPS to fuser . . . . . . . . . . . . . . . . . . . . . . . .7-9
Assembly, duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Sensor, smart button . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11, 7-21
Sensor, toner level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11, 7-21
Plate assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Bracket, paper sensor . . . . . . . . . . . . . . . . . . . . . . . . . 7-15, 7-21
Roll, paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Assembly, paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Guide, entrance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Bracket, shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Roller, paper guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Damper, tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Feet, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Cable assembly, output full (and fuser exit) . . . . . . . . . . . . . .7-11
Connector, 3-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Connector, 2-pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Latch, door 3 latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
Parts pack, (screws and E-rings) . . . . . . . . . . . . . . . . . . 7-7, 7-17
Hinge, pivot (quantity 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
Assembly, fuser (220 V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Bracket, body-tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Fuser assembly, paper guide . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Drawer assembly, 250-sheet . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
I-6 Service Manual
7001-001
56P0675
56P0676
56P0677
56P0678
56P0680
56P0681
56P0682
56P0693
56P0694
56P0695
56P0696
56P0697
56P0698
56P0699
56P1248
56P1250
56P1251
56P1418
56P1427
56P2181
56P2231
56P2250
56P2251
56P2252
56P2254
56P2255
56P2256
56P2257
56P2258
56P2259
56P2260
56P2261
56P2262
56P2263
56P2264
56P2265
56P2266
56P2267
56P2268
56P2269
56P2270
56P2271
56P2272
56P2273
56P2275
Drawer assembly, 500-sheet . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Spring, fuser exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Flags, stack control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Tray, 500-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Flap, paper holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Tray, 250-sheet label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Sensor cable, output full . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Roller asm., reference backup (top front and rear) . . . . . . . . 7-15
DIMM, 4MB SDRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, 8MB SDRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM 16MB SDRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, 32MB SDRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, 64MB SDRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, 128MB SDRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, Japanese 8MB font . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, Simplified Chinese font . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, Traditional Chinese font . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, 32MB flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, Optra Forms 32MB flash . . . . . . . . . . . . . . . . . . . . . . 7-23
Assembly, roller (MPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
DIMM, Korean font . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Idler, R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Idler, R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Feeder assembly, auto document . . . . . . . . . . . . . . . . . . . . . 7-29
Cover, separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Pad, pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Cover, ADF upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Cover assembly, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Cover assembly, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Cover, ADF right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Cover, ADF left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Panel, operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Cover, scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Tray assembly, document . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Cover, flatbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Cover assembly, front with display (with logo) . . . . . . . . . . . . 7-3
Cushion, scan cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Cover, right scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Cover, left scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Belt, timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Carriage, CCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Card, SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27, 7-31
Motor assembly, flatbed with cable . . . . . . . . . . . . . . . . 7-27, 7-31
Cable assembly, main harness . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Cable assembly, SCU-RIP . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
I-7
7001-001
56P2276
56P2276
56P2277
56P2278
56P2278
56P2283
56P2284
56P2285
56P2286
56P2287
56P2508
56P2517
56P2539
56P2649
56P2734
56P2735
70G0478
7370971
99A0545
99A1683
99A1684
99A1685
99A1686
99A1757
99A1758
99A1759
99A1774
Cable assembly, OPU-RIP . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Cable, OPU-RIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Cable assembly, SCU AFE-RIP . . . . . . . . . . . . . . . . . . . . . . . 7-31
Cable assembly, SCU-CCD . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
Cable, CCD-SCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
Cage, card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
Power supply, 220 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Power supply, 110 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Overlay, operator panel (FIGSD) . . . . . . . . . . . . . . . . . . . . . .7-27
Overlay, operator panel (DNSFBP) . . . . . . . . . . . . . . . . . . . . 7-27
Cover assembly, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
Cable assembly, power SCU-RIP . . . . . . . . . . . . . . . . . . . . . 7-31
Motor assembly, ADF with cable to SCU . . . . . . . . . . . . 7-31, 1-1
Roller kit, ADF pick and separator . . . . . . . . . . . . . . . . . . . . . 7-29
Card, RIP—NA (resistive) . . . . . . . . . . . . . . . . . . . 7-9, 7-11, 7-31
Card, RIP—EU (reactive) . . . . . . . . . . . . . . . . . . . 7-9, 7-11, 7-31
Power cord - see listing in parts catalog . . . . . . . . . . . . . . . . 7-13
Kit, field relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Adapter, external serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
DIMM, Optra Forms 2MB flash . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, Optra Forms 4MB flash . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, Optra Forms 8MB flash . . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, Optra Forms 16MB flash . . . . . . . . . . . . . . . . . . . . . . . 7-23
DIMM, 2MB flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
DIMM, 4MB flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
DIMM, 8MB flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
DIMM, 16MB flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
I-8 Service Manual