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Edition: June 1, 2009
Lexmark™ X642e, X644e, X646e MFP
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• 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.
7002-xxx
Edition: June 1, 2009
The following paragraph does not apply to any country where such provisions are inconsistent with local law :
LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time.
Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road,
Lexington, Kentucky 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.
Lexmark, Lexmark with diamond design, MarkNet, and MarkVision are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
PrintCryption is a trademark of Lexmark International, Inc.
LEXFAX is a service mark of Lexmark International, Inc.
Other trademarks are the property of their respective owners.
© 2009 Lexmark International, Inc.
All rights reserved.
UNITED STATES GOVERNMENT RIGHTS
This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense.
P/N 12G9662
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Table of contents
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Understanding the MFP operator panel
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Table of contents iii
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Sub error codes for 8xx, 9 xx,
and 2 xx error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
User attendance messages—paper jams and paper handling errors (2
xx .
xx ) . . . . . . . . . . . . . . . . . . 2-57
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95
iv Service Manual
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Table of contents v
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Parallel strobe adjustment (Par
x Strobe Adj) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Configuration menu (CONFIG MENU)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
vi Service Manual
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Scanner ADF and flatbed removals
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Table of contents vii
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
viii Service Manual
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Cleaning the scanner glass, cushions, and strips
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2
Assembly 2: Cover—printer (models X644e and X646e)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-8
7-10
7-12
7-14
Assembly 7: Scanner automatic document feeder (ADF)—pickup
. . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Assembly 8: Scanner ADF—paper feed
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Table of contents ix
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7-18
7-19
Assembly 11: Scanner ADF—sensors
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
7-24
7-25
Assembly 15: Paper feed—multipurpose feeder
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Assembly 16: Paper feed—alignment
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Assembly 17: Integrated 500-sheet paper tray
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
7-32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
7-36
7-38
Assembly 22: Electronics—card assemblies
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
7-42
7-43
7-44
7-45
Assembly 27: Cabling diagram 4—model X642e
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
Assembly 28: Cabling diagram 4—models X644e/X646e
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
7-50
Assembly 30: Cabling diagram 6—model X642e
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Assembly 31: Cabling diagram 6—models X644e/X646e
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
7-56
Assembly 33: Cabling diagram 8—model X642e
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
Assembly 34: Cabling diagram 8—models X644e/X646e
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Assembly 35: Optional 250-sheet paper drawer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
7-60
Assembly 37: Optional 500-sheet paper drawer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
7-62
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
7-66
7-68
7-69
7-70
7-71
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-9 x Service Manual
Laser notices
A laser notice label may be affixed to this MFP.
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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.
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 .
Laser notices xi
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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.
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.
xii Service Manual
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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.
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 notices xiii
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Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av
Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.
Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer.
Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.
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.
xiv Service Manual
Japanese Laser Notice
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Laser notices xv
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Korean Laser Notice xvi Service Manual
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Safety information
• The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts.
• The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
• There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.
•
CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Consignes de sécurité
• La sécurité de ce produit repose sur des tests et des agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.
• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié.
•
Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.
• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou faites preuve de vigilance si l'exécution de la tâche exige que le produit reste sous tension.
Norme di sicurezza
• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti.
•
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
• Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie.
• ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto.
Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.
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7002-xxx
Sicherheitshinweise
• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine
Verantwortung oder Haftung für die Sicherheit übernommen.
• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende
Vorsichtsmaßnahmen treffen.
• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem
Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des
Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.
Pautas de Seguridad
• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.
• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento.
• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.
• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con él, debe conectarlo.
Informações de Segurança
• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas.
• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas.
• Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.
Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.
• CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para realizar a tarefa necessária.
-xviii Service Manual
7002-xxx
Informació de Seguretat
• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics.
El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades.
• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui.
• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.
• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.
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7002-xxx
Preface
This manual contains maintenance procedures for service personnel. It is divided into the following chapters:
1.
General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
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 printer problems.
4.
Repair information provides instructions for making printer adjustments and removing and installing
FRUs.
5.
Connector locations uses illustrations to identify the connector locations and test points on the printer.
6.
Preventive maintenance contains the lubrication specifications and recommendations to prevent problems.
7.
Parts catalog contains illustrations and part numbers for individual FRUs.
Appendix A contains service tips and information.
Conventions
Note: A note provides additional information.
Warning: A warning identifies something that might damage the product hardware or software.
There are several types of caution statements:
CAUTION
A caution identifies something that might cause a servicer harm.
CAUTION
This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
CAUTION
This type of caution indicates a hot surface.
CAUTION
This type of caution indicates a tipping hazard.
-xx Service Manual
7002-xxx
1. General information
The Lexmark™ X642e, X644e, and X646e are All-In-One laser MFPs that provide print, copy, scan, and fax functions designed to attach to IBM-compatible personal computers and most computer networks. The operator panel is touch-sensitive and allows the user to adjust the viewing angle.
The Lexmark X64 x e laser MFPs are available in the following models:
Model name
Lexmark X644e
Lexmark X642e
Lexmark X642e
Lexmark X644e
Lexmark X646e
Lexmark X646e
Lexmark X644e
Lexmark X642e
Lexmark X642e
Lexmark X644e
Lexmark X646e
Lexmark X646e
Configuration
Network
Network
Network, modem
Network, modem
Network, hard disk
Network, modem, hard disk
HV, network
HV, network
HV, network, modem
HV, network, modem
HV, network, hard disk
HV, network, hard disk
Machine type
7002-001
7002-003
7002-005
7002-011
7002-101
7002-111
7002-002
7002-004
7002-006
7002-012
7002-102
7002-112
Maintenance approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to determine the MPF problem and repair the failure. After you complete the repair, perform tests as needed to verify the repair. See
General information 1-1
7002-xxx
Configured models
The following illustrations show and compare standard X642e and X644e MFPs and X642e and X644e MFPs configured with a duplex unit and a 500-sheet drawer. Other print media handling options are also available.
Model X644e or X646e MFP
Standard
Model X644e or X646e MFP
With duplex and drawer
Scanner
Standard output bin
Control panel
Multipurpose feeder
Tray 1 (integrated tray or standard tray)
Duplex unit
Tray 2
(500 sheets)
Tray 1 (integrated tray or standard tray)
Model X642e MFP
Standard
Model X642e MFP
With duplex and drawer
1-2 Service Manual
CAUTION
Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet drawer. Certain other configurations also must have a printer stand or printer base. More information is available on our Lexmark
Web site at www.lexmark.com/multifunctionprinters .
7002-xxx
Options
The following options are available. Some options are not available in every country or region. Contact your point of purchase for options available in your country or region.
• Memory options of 128MB, 256MB, and 512MB SDRAM
• Flash memory options of 32MB and 64MB
• Hard disk—20GB+ with adapter (model X646e only)
• Integrated network options
– Token-Ring
– Ethernet
– External serial adapter
– IPDS card assembly and SCS/TNe
– PRESCRIBE card assembly
– Bar code card assembly
– Parallel interface card
– MarkNet™ Professional Print Servers—Only one active internal networking connection is supported.
Installing an optional Lexmark MarkNet Professional N800 Series internal print server makes the server the active network connection and disables the standard Ethernet port.
– Lexmark PrintCryption™ card
– Forms card (single-byte and Simplified Chinese)
• Media handling operations
– 250- and 500-sheet paper trays of A4, letter, A5, B5, Executive, folio, statement, and legal size
– 250- and 400-sheet universally adjustable trays
– 250- and 500-sheet paper drawers
– 400-sheet universally adjustable tray
– 2000-sheet high-capacity feeder—always used below any other drawer.
– Envelope feeder
– Duplex option—500-sheet (For Lexmark X644e and Lexmark X646e with integrated 500-sheet output tray)
• Application solutions
– Bar code card
– Lexmark Forms Card Software
– IPDS
– PRESCRIBE emulation card
– PrintCryption
• DBCS font cards
– Simplified Chinese
– Traditional Chinese
– Japanese
– Korean
General information 1-3
7002-xxx
Specifications
General
MFP specifications
Scanner
Scanner type
Scanner technology
Light sources
Max optical resolution
Scan area (flatbed)
Scanner ADF
ADF type
ADF optical resolution
Document capacity
Media thickness
Media weight
ADF scan area
Printer
Print technology
Fax
Modem (in models with modem)
Resolution
• 1200 x 1200 dpi
• 2400 Image Quality
• 1200 Image Quality
• 600 x 600 dpi
Data streams
• PostScript 3 emulation
• PCL 6 emulation
• PPDS migration tool
• PDF v1.5 emulation
Lexmark X642e Lexmark X644e/X646e
Color flatbed scanner with ADF
Charge coupled device (CCD)
Two Cold Cathode Fluorescent Lamp
(CCFL) and one CCD module per scanner
600 x 600 dpi maximum (mono)
600 x 300 dpi (color) with final resolution 300 x 300 dpi
8.5 in. x 14 in. (216 mm x 355.6 mm) maximum
Color flatbed scanner with ADF
Charge coupled device (CCD)
Two CCFL and two CCD modules per scanner
600 x 600 dpi maximum (mono)
600 x 300 dpi (color) with final resolution 300 x 300 dpi
8.5 in. x 14 in. (216 mm x 355.6 mm) maximum
Simplex ADF with C-path Single pass duplex ADF with C-path
600 x 600 dpi maximum 600 x 600 dpi maximum
50 sheets (assuming 20 lb./75 g/m
2
) 50 sheets (assuming 20 lb./75 g/m
2
)
0.05 mm (minimum) to 0.15 mm
(maximum)
15 lb (56 g/m
2
) to 32 lb (120 g/m
2
)
0.05 mm (minimum) to 0.15 mm
(maximum)
15 lb (56 g/m
2
) to 32 lb (120 g/m
2
)
8.5 in. x 14.0 in. (216 mm x 355 mm) 8.5 in. x 14.0 in. (216 mm x 355 mm)
Hot roll fuser Hot roll fuser
Built-in Group 3 compatible, full function fax 33,600 bps, Max V.34 half duplex
Built-in Group 3 compatible, full function fax 33,600 bps, Max V.34 half duplex
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7002-xxx
Memory configuration
Models
Memory type
Lexmark X642e Lexmark X644e Lexmark X646e
Standard DRAM (MB)
Optional memory (MB)
(One slot—100 pin DDR SDRAM unbuffered DIMMs)
Maximum (MB)
Optional flash memory (MB)
128
640
256
128, 256, and 512 available
768
32 and 64 available
256
768
Hard disk N/A N/A <20GB
Note: One firmware card and one flash memory card are supported. Either slot supports both card types.
Depending upon the options and features used, additional memory may be required to optimize performance.
Recommended operating clearances
Dimension Measurement
Left
Right
Front
Rear
12 in. (30.5 cm)
8 in. (20.3 cm)
20 in. (50.8 cm)
8 in. (20.3 cm)
Top* 12 in. (30.5 cm)
* Allow clearance above the printer front door clearance and for adding options, such as additional input drawers.
General information 1-5
7002-xxx
Dimensions
Description
Printer
Lexmark X642e
Height Width
Lexmark X644e
Lexmark X646e
Lexmark X646e (with duplex and
500-sheet option)
Options
Duplex 500-page option
28.0 in.
(710 mm)
28.0 in.
(710 mm)
28.0 in.
(710 mm)
35.0 in.
(890 mm)
22.0 in.
(560 mm)
22.0 in.
(560 mm)
22.0 in.
(560 mm)
22.0 in.
(560 mm)
250-Sheet drawer
500-Sheet drawer
2,000-Sheet drawer
Envelope option (closed position)
2.0 in.
(51 mm)
3.5 in.
(90 mm)
5.2 in.
(134 mm)
15.0 in.
(381 mm)
*
15.7 in.
(398 mm)
15.7 in.
(398 mm)
15.7 in.
(398 mm)
15.7 in.
(398 mm)
*
Envelope option (support fully extended)
MFP Stand with Cabinet
*
Low Profile MFP Stand
MFP Stand without Cabinet
Stability Enhanced Caster Base
31.5 in.
(800 mm)
22.8 in.
(579 mm)
31.5 in.
(800 mm)
6.0 in.
(152 mm)
10 Inch Cabinet Option 10.0 in.
(255 mm)
* Envelope option fits within height and width of printer.
*
22.4 in.
(569 mm)
22.4 in.
(569 mm)
22.4 in.
(569 mm)
27 in.
(685 mm)
15.7 in.
(397.6 mm)
Depth
25.4 in.
(645 mm)
25.4 in.
(645 mm)
25.4 in.
(645 mm)
26.0 in.
(660 mm)
24.1 in.
(595 mm)
18.0 in.
(457 mm)
19.0 in.
(520 mm)
18.0 in.
(457 mm)
7.72 in.
(196 mm)
12.28 in.
(312 mm)
24.5 in.
(622 mm)
24.5 in.
(594 mm)
24.5 in.
(622 mm)
27.0 in.
(686 mm)
17.54 in.
(445.7 mm
Weight
80.0 lb
(34.9 kg)
83.0 lb
(37.7 kg)
84.5 lb
(46.7 kg)
103 lb
(46.7 kg)
4 lb
(1.8 kg)
64 lb
(29.0 kg)
45 lb
(20.4 kg)
64 lb
(28.1 kg)
25 lb
(11.3 kg)
17.1 lb.
(7.8 kg)
11.3 lb
(5.1 kg)
6 lb
(2.7 kg)
7 lb
(3.2 kg)
31 lb
(14.1 kg)
4 lb
(1.8 kg)
1-6 Service Manual
7002-xxx
Power requirements
Average nominal power requirements for the base printer configuration (110 volt). Power levels are shown in watts (W). Maximum current is given in Amperes (A).
Printing states
Off
Idle—average power
Power Saver on
Power Saver off
Continuous copying
Continuous printing
Printing—maximum current
100 V
120 V
230 V
Lexmark X642e
0 W
30 W
105 W
650 W
800 W
12.3 A
10.5 A
5.4 A
Lexmark X644e
.05 W
20 W
90 W
875 W
675 W
7.8 A
7.2 A
3.4 A
Lexmark X646e
.05 W
20 W
95 W
875 W
830 W
8.9 A
8.0 A
4.1 A
Electrical specifications
Low voltage model
• 100 to 127 V ac at 50 to 60 Hz nominal
• 90 to 137 V ac, extreme
High voltage model
• 220 to 240 V ac at 50 to 60 Hz nominal (not available in all countries or regions)
• 198 to 259 V ac, extreme
Notes:
• Using a power converter or inverter is not recommended.
• All models are ENERGY STAR qualified.
• All models ship with Power Save Mode on.
• The default timeout to power saver is 30 minutes for models X644e/X646e and 45 minutes for model
X642e.
General information 1-7
7002-xxx
Environment
Printer temperature and humidity
•
Operating
–
Temperature: 16 to 32° C (60° to 90° F)
–
Relative humidity: 8 to 80%
–
Altitude: 10,000 ft. (0 to 3,048 meters)
•
Storage and shipping environment (packaged)
–
Temperature: -40° to 43° C (-40° to 110° F)
–
Relative humidity: 5% to 95%
–
Altitude: equivalent to 10,300 meters (0 to 34,000 feet)
•
Storage environment (unpacked)
–
Temperature: 0° to 40° C (32° to 104° F)
–
Relative humidity: 5% to 80%
Acoustics
All measurements are made in accordance with ISO 7779 and conform with ISO 9296.
Emission sound pressure level (dBA)
Mode
Bystander position average (LpAm)
Standing Operator
Position (LpAm)
Printing
Copying
Scanning
Ready
56
57
52
30
N/A
62
59
N/A
Note: Measurements apply to 300 dpi, 600 dpi, and 1200 dpi printing.
Declared sound power level (Bels)
(LpAm)
7.0
7.2
6.8
4.5
1-8 Service Manual
7002-xxx
Media specifications
Paper and specialty media guidelines
Print media is paper, card stock, transparencies, labels, and envelopes. This printer provides high quality printing on a variety of print media. You must consider a number of things concerning print media before you print, including:
•
Supported print media
•
Selecting print media
•
Storing print media
•
Avoiding jams
For more details about the types of paper and specialty media your printer supports, refer to the Card Stock &
Label Guide available on our Lexmark Web site at www.lexmark.com.
We recommend that you try a limited sample of any paper or specialty media you are considering using with the printer before purchasing large quantities.
Supported print media
The following tables provide information on standard and optional sources for both input and output trays and bins.
• Print media sizes
• Print media weights
• Media weights supported in optional output bins
Note: If you use a print media size not listed, select the next larger size.
Print media sizes
Legend
✓ — indicates support
Print media size
Dimensions
A4
A5
JIS B5
Letter
210 x 297 mm (8.27 x 11.7 in.)
148 x 210 mm (5.83 x 8.27 in.)
182 x 257 mm (7.17 x 10.1 in.)
215.9 x 279.4 mm (8.5 x 11 in.)
✓ ✓ ✓ ✓ ✓ ✓
✓ ✓ ✓ ✓ ✓ ✓
✓ ✓ ✓ ✓ ✓ ✓
✓ ✓ ✓ ✓ ✓ ✓
✓
✓
✓
✓
✓
✓
✓
✓
Legal 215.9 x 355.6 mm (8.5 x 14 in.)
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
1
This size does not appear in the Paper Size menu until Tray Size Sensing is turned off. Refer to the User
Guide for more information.
2
This size setting formats the page for 215.9 x 355.6 mm (8.5 x 14 in.) unless the size is specified by the software application.
General information 1-9
7002-xxx
Legend
✓ — indicates support
Print media size
Dimensions
Executive
Folio
1
Statement
1
Universal
2
184.2 x 266.7 mm (7.25 x 10.5 in.)
216 x 330 mm (8.5 x 13 in.)
139.7 x 215.9 mm (5.5 x 8.5 in.)
✓ ✓ ✓ ✓ ✓ ✓
✓ ✓ ✓ ✓ ✓ ✓
✓ ✓ ✓ ✓ ✓
✓ ✓ ✓ ✓ ✓
✓ ✓
✓ ✓
✓
✓
139.7 x 210 mm to 215.9 x 355.6 mm
(5.5 x 8.27 in. to 8.5 x 14 in.)
69.85 x 127 mm to 215.9 x 355.6 mm
(2.75 x 5 in. to 8.5 x 14 in.)
✓ ✓
148 x 182 mm to 215.9 x 355.6 mm
(5.83 x 7.17 in. to 8.5 x 14 in.)
✓
76.2 x 127 mm to 215.9 x 355.6 mm
(3 x 5 in. to 8.5 x 14 in.)
✓
76.2 x 177.8 mm to 215.9 x 355.6 mm
(3 x 7 in. to 9.01 x 14 in.)
✓
7 ¾ Envelope
9 Envelope
10 Envelope
DL Envelope
98.4 x 190.5 mm (3.875 x 7.5 in.)
98.4 x 225.4 mm (3.875 x 8.87 in.)
104.8 x 241.3 mm (4.12 x 9.5 in.)
110 x 220 mm (4.33 x 8.66 in.)
✓
✓
✓
✓
✓
✓
✓
✓
B5 Envelope
C5 Envelope
176 x 250 mm (6.93 x 9.84 in.)
162 x 229 mm (6.38 x 9.01 in.)
✓
✓
✓
✓
Other Envelope
1
98.4 x 162 mm to 176 x 250 mm
(3.87 x 6.38 in. to 6.93 x 9.84 in.)
✓ ✓ ✓
1
This size does not appear in the Paper Size menu until Tray Size Sensing is turned off. Refer to the User
Guide for more information.
2
This size setting formats the page for 215.9 x 355.6 mm (8.5 x 14 in.) unless the size is specified by the software application.
✓
✓
✓
✓
✓
✓
1-10 Service Manual
Print media types
7002-xxx
Print media
Paper
✓ ✓ ✓ ✓ ✓ ✓
Card stock
Transparencies
✓
✓
✓
✓
✓
✓
Vinyl labels
*
Paper labels
*
✓
✓
✓
✓
✓
✓
Polyester label
*
Dual-web and integrated labels*
✓
✓
✓
✓
✓
✓
*
Printing label applications on the MFP requires a special label fuser cleaner. The label fuser cleaner is included with a special label cartridge for label applications.
✓
✓
✓
✓
✓
✓
Print media weights
Print media
Paper
Card stock— maximum (grain long)
1
Card stock— maximum (grain short)
1
Transparencies
Type
Xerographic or business paper
Index Bristol
Tag
Cover
Index Bristol
Tag
Cover
Laser printer
Integrated tray and optional
500-sheet drawer
60 to 176 g/m
2 grain long
(16 to 47 lb bond)
163 g/m
2
(90 lb)
163 g/m
2
(100 lb)
176 g/m
2
(65 lb)
199 g/m
2
(110 lb)
203 g/m
2
(125 lb)
216 g/m
2
(80 lb)
138 to 146 g/m
2
(37 to 39 lb bond)
Print media weight
Multipurpose feeder and optional
250-sheet drawer
60 to 135 g/m
2 grain long
(16 to 36 lb bond)
120 g/m
2
(67 lb)
120 g/m
2
(74 lb)
135 g/m
2
(50 lb)
163 g/m
2
(90 lb)
163 g/m
2
(100 lb)
176 g/m
2
(65 lb)
138 to 146 g/m
2
(37 to 39 lb bond)
Envelope feeder n/a n/a
General information 1-11
7002-xxx
Print media weight
Print media Type Integrated tray and optional
500-sheet drawer
Multipurpose feeder and optional
250-sheet drawer
Envelope feeder
Labels— maximum
4
Paper
Dual-web paper
180 g/m
(48 lb bond)
180 g/m
2
2
(48 lb bond)
163 g/m
2
(43 lb bond)
Note: Not supported in the multipurpose feeder.
163 g/m
2
(43 lb bond)
Note: Not supported in the multipurpose feeder.
n/a
Polyester
Vinyl
5
220 g/m
2
(59 lb bond)
300 g/m
2
(92 lb liner)
220 g/m
2
(59 lb bond)
Note: Not supported in the multipurpose feeder.
260 g/m
2
(78 lb liner)
Note: Not supported in the multipurpose feeder.
140 to 175 g/m
2
Integrated forms Pressure- sensitive area
(must enter the MFP first)
140 to 175 g/m
2
Paper base
(grain long)
75 to 135 g/m
2
(20 to 36 lb bond)
75 to 135 g/m
2
(20 to 36 lb bond)
Envelopes
100% cotton content maximum weight—24 lb
Sulfite, woodfree, or up to
100% cotton bonds
Not recommended 60 to 105 g/m
2
(16 to 28 lb bond)
2, 3
60 to 105 g/m
(16 to 28 lb bond)
3
2
Note: 28 lb envelopes are limited to 25% cotton content.
1
Grain short is preferred for papers over 135 g/m
2
.
2
Includes envelopes fed from the multipurpose feeder only.
3
28 lb bond envelopes are limited to 25% cotton content.
4
Printing label applications on the MFP requires a special label fuser cleaner.
5
Information on whether your vinyl label converter has passed Lexmark criteria is available at the Lexmark
Web site ( www.lexmark.com) ; search for “converter list.” You can also check the Lexmark Automated Fax system (LEXFAX
SM
).
1-12 Service Manual
7002-xxx
Selecting print media
Selecting the appropriate print media for the MFP helps you avoid printing problems. The following sections contain guidelines for choosing the correct print media for the MFP.
• Paper
• Transparencies
• Envelopes
• Labels
• Card stock
Paper
For the best print quality, use 75 g/m
2
(20 lb) xerographic, grain long paper. Try a sample of any paper you are considering using with the MFP before buying large quantities.
When loading paper, note the recommended print side on the paper package, and load paper accordingly.
Paper characteristics
The following paper characteristics affect print quality and reliability. We recommend that you follow these guidelines when evaluating new paper stock.
For detailed information, see the Card Stock & Label Guide located on the Lexmark Web site at www.lexmark.com.
The laser printing process heats paper to high temperatures of 230°C (446°F). For Magnetic Ink Character
Recognition (MICR) applications and for non-MICR applications, use only paper able to withstand these temperatures without discoloring, bleeding, or releasing hazardous emissions. Check with the manufacturer or vendor to determine whether the paper you have chosen is acceptable for laser printers.
Weight
The MFP can automatically feed paper weights from 60 to 176 g/m
2
(16 to 47 lb bond) grain long in the integrated and optional 500-sheet trays and paper weights from 60 to 135 g/m
2
(16 to 36 lb bond) grain long in the multipurpose feeder and optional 250-sheet trays. Paper lighter than 60 g/m
2
(16 lb) might not be stiff enough to feed properly, causing jams. For best performance, use 75 g/m
2
(20 lb bond) grain long paper. When using paper narrower than 182 x 257 mm (7.2 x 10.1 in.), make sure the weight is greater than or equal to
90 g/m
2
(24 lb bond).
Unacceptable paper
The following papers are not recommended for use with the MFP:
•
Some chemically treated papers used to make copies without carbon paper, also known as carbonless papers, carbonless copy paper (CCP), or no carbon required (NCR) paper (see the Card Stock & Label
Guide located on the Lexmark Web site at www.lexmark.com for supported chemically treated papers)
• Preprinted papers with chemicals that may contaminate the MFP
• Preprinted papers that can be affected by the temperature in the MFP fuser
• Preprinted papers that require a registration (the precise print location on the page) greater than ±0.09 in., such as optical character recognition (OCR) forms
• In some cases, you can adjust registration with your software application to successfully print on these forms.
• Coated papers (erasable bond), synthetic papers, thermal papers
• Rough-edged, rough or heavily textured surface papers or curled papers
• Recycled papers containing more than 25% post-consumer waste that do not meet DIN 19 309
• Recycled paper having a weight less than 60 g/m
2
(16 lb)
• Multiple-part forms or documents
General information 1-13
7002-xxx
Transparencies
The MFP can print directly on transparencies designed for use in laser printers. Print quality and durability depend on the transparency used. Always print samples on the transparencies you are considering before buying large quantities.
The Paper Type setting should be set to Transparency to help prevent jams. In Macintosh, be sure to set the
Paper Type to Transparency in the Print dialog on the Imaging choice in the Copies & Pages pop-up menu.
Use transparencies designed specifically for laser printers. Check with the manufacturer or vendor to determine whether your transparencies are compatible with laser printers that heat transparencies to 230°C (446°F). Use only transparencies that are able to withstand these temperatures without melting, discoloring, offsetting, or releasing hazardous emissions. For detailed information, see the Card Stock & Label Guide , which is available on the Lexmark Web site at www.lexmark.com.
Transparencies can be fed automatically from the multipurpose feeder and all standard and optional trays, except the 2000-sheet drawer. Before loading transparencies, fan the stack to prevent sheets from sticking together.
Be careful when you handle transparencies. Fingerprints on the surface of the transparency cause poor print quality.
Envelopes
You can load up to 10 envelopes in the multipurpose feeder and 85 envelopes in the envelope feeder. Try a sample of any envelopes you are considering using with the MFP before buying large quantities.
When printing on envelopes:
• To achieve the best possible print quality, use only high-quality envelopes that are designed for use in laser printers.
•
Set the Paper Size/Type in the Paper menu to MP Feeder, Manual Env, or Env Feeder depending on the source you are using. Set the paper type to Envelope, and select the correct envelope size from the operator panel, the MFP driver, or from MarkVision™ Professional.
• For best performance, use envelopes made from 75 g/m
2
(20 lb bond) paper. You can use up to 105 g/m
2
(28 lb bond) weight for the multipurpose feeder or 105 g/m
2
(28 lb bond) weight for the envelope feeder as long as the cotton content is 25% or less. Envelopes with 100% cotton content must not exceed 90 g/m
2
(24 lb bond) weight.
• Use only new, undamaged envelopes.
• For best performance and to minimize jams, do not use envelopes that:
– Have excessive curl or twist.
– Are stuck together or damaged in any way.
– Contain windows, holes, perforations, cutouts or embossing.
– Use metal clasps, string ties, or metal folding bars.
– Have an interlocking design.
– Have postage stamps attached.
– Have any exposed adhesive when the flap is in the sealed or closed position.
– Have nicked edges or bent corners.
– Have rough, cockle, or laid finishes.
• Use envelopes that can withstand temperatures of 230°C (446°F) without sealing, excessive curling, wrinkling, or releasing hazardous emissions. If you have any doubts about the envelopes you are considering using, check with the envelope supplier.
• Load only one size of envelope at a time in the envelope feeder.
• A combination of high humidity (over 60%) and the high printing temperatures may seal the envelopes.
1-14 Service Manual
7002-xxx
Labels
The MFP can print on many labels designed for use with laser printers. These labels are supplied in letter size,
A4 size, and legal size sheets. Label adhesives, face sheet (printable stock), and topcoats must be able to withstand temperatures of 230°C (446°F) and pressure of 25 pounds per square inch (psi).
Try a sample of any labels you are considering using with the MFP before purchasing a large quantity.
For detailed information on label printing, characteristics, and design, see the Card Stock & Label Guide available on the Lexmark Web site at www.lexmark.com/publications.
Note: Labels are one of the most difficult print media for laser MFPs. All MFP models require a special fuser cleaner for label applications to optimize feed reliability.
After printing approximately 10,000 pages of labels (or each time you replace the print cartridge), complete the following steps to maintain MFP feeding reliability:
1.
Print five sheets of paper.
2.
Wait approximately five seconds.
3.
Print five more sheets of paper.
When printing on labels:
• Set the Paper Size/Type menu item to Labels in the Paper menu. You can set the Paper Size/Type from the MFP operator panel, the MFP driver, or from MarkVision Professional.
• Feed vinyl labels from the standard 250- or 500-sheet trays or the optional 250- or 500-sheet drawers. For vinyl labels, set the Paper Type to Labels, the Labels Texture to Smooth, and the Label Weight to Heavy, or set the Paper Type to vinyl labels and the texture and weight to normal.
• Do not load labels with paper or transparencies in the same source; mixing print media can cause feeding problems and print quality problems.
• Do not use label sheets with a slick backing material.
• Use full label sheets. Partial sheets may cause labels to peel off during printing, resulting in a jam. Partial sheets also contaminate the MFP and your cartridge with adhesive, and could void the MFP and cartridge warranties.
• Use labels that can withstand temperatures of 230°C (446°F) without sealing, excessive curling, wrinkling, or releasing hazardous emissions.
• Do not print within 1 mm (0.04 in.) of the edge of the label, of the perforations, or between die-cuts of the label.
• Do not use label sheets that have adhesive to the edge of the sheet. We recommend zone coating of the adhesive at least 1 mm (0.04 in.) away from edges. Adhesive material contaminates the MFP and could void the warranty.
• If zone coating of the adhesive is not possible, a 1.6 mm (0.1 in.) strip should be removed on the leading and driver edge, and a non-oozing adhesive should be used.
•
Remove a 1.6 mm (0.1 in.) strip from the leading edge to prevent labels from peeling inside the MFP.
•
Portrait orientation is preferred, especially when printing bar codes.
•
Do not use labels that have exposed adhesive.
General information 1-15
7002-xxx
Card stock
Card stock is single ply, and has a large array of properties, such as the moisture content, thickness, and
the preferred weight and for the grain direction of print media.
Try a sample of any card stock you are considering using with the MFP before purchasing a large quantity.
After printing approximately 10,000 pages of card stock (or each time you replace the print cartridge), complete the following steps to maintain MFP feeding reliability:
1.
Print five sheets of paper.
2.
Wait approximately five seconds.
3.
Print five more sheets of paper.
When printing on card stock:
• Set the Paper Type menu item in the Paper menu to Card Stock from the operator panel, from the MFP driver, or from MarkVision Professional.
• Be aware that preprinting, perforation, and creasing can significantly affect the print quality and cause print media handling or jamming problems.
• Avoid using card stock that may release hazardous emissions when heated.
• Do not use preprinted card stock manufactured with chemicals that may contaminate the MFP. Preprinting introduces semi-liquid and volatile components into the MFP.
•
We recommend the use of grain short card stock.
Storing print media
Use the following guidelines to avoid paper feeding problems and uneven print quality.
• Store paper in an environment where the temperature is approximately 21°C (70°F) and the relative humidity is 40%.
• Store cartons of paper on a pallet or shelf rather than directly on the floor.
• If you store individual packages of paper out of the original carton, make sure they rest on a flat surface so the edges do not buckle or curl.
• Do not place anything on top of paper packages.
• Store paper in its original wrapper until you load it into the MFP.
Avoiding jams
Use appropriate print media (paper, transparencies, labels, and card stock) to help ensure trouble-free printing.
Note: Try a limited sample of any print media you are considering using with the MFP before purchasing large quantities.
By selecting the appropriate print media and loading it properly, you can avoid most jams.
The following hints can help you avoid jams:
• Use only recommended print media.
• Do not overload the print media sources. Make sure the stack height does not exceed the maximum height indicated by the stack line on the labels in the sources.
• Do not load wrinkled, creased, damp, or curled print media.
• Flex, fan, and straighten print media before you load it. If jams do occur with print media, try feeding one sheet at a time through the multipurpose feeder.
• Do not use print media that you have cut or trimmed yourself.
• Do not mix print media sizes, weights, or types in the same print media source.
• Make sure the recommended print side is loaded in the source according to your simplex or duplex needs.
1-16 Service Manual
7002-xxx
•
Keep print media stored in an acceptable environment. See “Storing print media” on page 1-16 .
• Do not remove trays during a print job.
• Push all trays in firmly after loading them.
• Make sure the guides in the trays are properly positioned for the size of print media you have loaded. Make sure the guides are not placed too tightly against the stack of print media.
• If a jam occurs, clear the entire media path.
Tools required
Flat-blade screwdrivers, various sizes
Phillips screwdrivers, various sizes
7/32 inch open-end wrench
7.0 mm nut driver
5.5 mm wrench
Needlenose pliers
Diagonal side cutters
Spring hook
Feeler gauges
Analog or digital multimeter
Parallel wrap plug 1319128
Twinax/serial debug cable 1381963
Flash light (optional)
General information 1-17
7002-xxx
Acronyms
PC
PIN
PJL
POR
POST
PP
PWM
RIP
LED
LES
LVPS
MDC
MFP
MPF
NVRAM
OPT
ADF
AIO
CCD
CRU
DIMM
DRAM
EP
EPROM
ESD
FRU
GB
HCIT
HVPS
ITC
LASER
LCD
SCC
SDRAM
SIMM
UAT
USB
V ac
V dc
Automatic Document Feeder
All-In-One
Charge Coupled Device (CCD)
Customer Replaceable Unit
Dual Inline Memory Module
Dynamic Random Access Memory
Electrophotographic process
Erasable Programmable Read-Only Memory
Electrostatic Discharge
Field Replaceable Unit
Gigabyte
High-Capacity Input Tray
High Voltage Power Supply
Internal Tray Card
Light Amplification by Stimulated Emission of Radiation
Liquid Crystal Display
Light-Emitting Diode
Lexmark Embedded Solution (applications)
Low Voltage Power Supply
Motor Driver Control
Multifunction Printer
Multipurpose Feeder
Nonvolatile Random Access Memory
Optical Sensor
Photoconductor
Personal Identification Number
Printer Job Language
Power-On Reset
Power-On Self Test
Parts Packet
Pulse Width Modulation
Raster Imaging Processor
Scanner Control Card
Synchronous Dynamic Random Access Memory
Single Inline Memory Module
Universally Adjustable Tray
Universal Serial Bus
Volts alternating current
Volts direct current
1-18 Service Manual
2. Diagnostic information
Start
7002-xxx must receive power in order to perform the task.
CAUTION
Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
Use the service error code, user status message, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer.
They will lead you to solutions or service checks, including use of various tests.
Symptom tables
available:
Service errors (8xx.xx and 9xx.xx’s)
If a service error code appears while you are working on the machine, go to
“Service error codes” on page 2-13
, and take the indicated action for that error.
Service error codes are indicated by a three-digit error code followed by a period and additional numbers in the format XXX.YY. In most cases, five digits are shown.
User status and attendance messages
•
User status messages provide the user with information on the current status of the printer.
Ready
displays on the first line of the display unless invoked, and then
Power Saver
displays. If a user status message is
displayed, go to “User status displays.” on page 2-38 .
• User attendance messages are indicated by a two or three-digit error code that provides the user with information that explains a problem with a print cartridge, paper jam, option, port, and so on. If a user error message displays, go to
“User attendance messages” on page 2-42
and
“User attendance messages—paper jams and paper handling errors (2xx.xx)” on page 2-57 .
Additional information
•
“Understanding the MFP operator panel” on page 2-2
•
•
“Diagnostics Menu” on page 3-2
•
“Configuration menu (CONFIG MENU)” on page 3-24
•
•
“Paper feed jams” on page 3-38
•
Diagnostic information 2-1
7002-xxx
Understanding the MFP operator panel
MFP and scanner settings can be changed several ways: through the MFP operator panel, the software application in use, the print driver, MarkVision Professional, or the Web pages. Settings changed from the application or print driver apply only to the job being sent to the MFP.
Changes made to print, fax, copy, and e-mail settings from an application override changes made from the operator panel.
If a setting cannot be changed from the application, use the MFP operator panel, MarkVision Professional, or the Web pages. Changing a setting from the MFP operator panel, MarkVision Professional, or the Web pages makes that setting the user default.
MFP operator panels
Model X642e
Models X644e/X646e
2-2 Service Manual
7002-xxx
Callout
1
2
3
4
5
6
7
8
0
10
Operator panel item
LCD
Indicator ligh t
Function
A liquid crystal display (LCD) which shows home screen buttons, menus, menu items, and values. Allows for making selections within Copy, Fax, and so on.
Gives information about the status of the MFP using the colors red and green.
Status Indicates
Off MFP power is off.
Blinking green MFP is warming up, processing data, or printing a job.
Solid green MFP is on, but idle.
Solid red Operator intervention is required.
0–9
Note: Referred to as the numeric keypad.
# (Pound or number character)
Dial Pause
Clear All
Start
Stop
Backspace
Asterisk (*)
Press these buttons to enter numbers when the LCD screen has a field that accepts the entry of numbers. Also, use these buttons to dial phone numbers for faxes.
Note: If a number is pressed while on the home screen without pressing the # button first, the Copy menu opens and changes the Copy Quantity.
Press this button:
• For a shortcut identifier.
• Within phone numbers. For a Fax number with a #, enter it twice — ##.
• From the home screen, the Fax Destination List menu item, E-mail Destination
List menu item, or Profile List menu item to access shortcuts.
Press to cause a two- or three-second dial pause in a fax number. The button only functions within the Fax menu or with fax functions.
Press from the home screen to redial a fax number.
When outside of the Fax menu, fax function, or home screen, pressing Dial Pause causes an error beep.
When sending a fax, in the Fax To: field, a Dial Pause press is represented by a comma (,).
When in the function menus, such as Copy, Fax, E-mail, and FTP, it returns all settings to their default values, and then returns the MFP to the home screen.
When in any other menu while the MFP is
Ready
, it cancels all changes that have not been submitted and returns the MFP to the home screen.
Press to initiate the current job indicated on the operator panel.
From the home screen, press it to start a copy job with the default settings.
If pressed while a job runs through the scanner, the button has no effect.
Press to cause the printing or scanning to stop.
During a scan job, the scanner finishes scanning the current page and then stops, which means paper may remain in the automatic document feeder (ADF).
During a print job, the print media path is cleared before the printing stops.
Stopping
appears on the operator panel during this process.
Within the Copy menu, which is accessed by touching the Copy button, press
Backspace to delete the right-most digit of the value in the Copy Count. The default value of 1 appears if the entire number is deleted by pressing Backspace numerous times.
Within the Fax Destination List, press Backspace to delete the right-most digit of a number entered manually. It also deletes an entire shortcut entry. Once an entire line is deleted, another press of Backspace causes the cursor to move up one line.
Within the E-mail Destination List, press Backspace to delete the character to the left of the cursor. If the entry is in a shortcut, the entire entry is deleted.
* is used as part of a fax number or as an alphanumeric character.
Diagnostic information 2-3
7002-xxx
Callout
11
12
13
14
15
Operator panel item
USB Direct interface
Function
The host Universal Serial Bus (USB) direct interface on the operator panel is used to plug in a USB flash memory device and print any Portable Document Format
(PDF) [.pdf file], Joint Photographic Experts Group (JPEG) [.jpeg or .jpg file],
Tagged Image File Format (TIFF) [.tiff or .tif file], Graphics Interchange Format
(GIF) [.gif file], Basic Multilingual Plane (BMP) [.bmp file], Portable Network
Graphics (PNG) [.png file], PiCture eXchange (PCX) [.pcx file], and PC Paintbrush
File Format [.dcx file] files.
The USB direct interface can also be used to scan a document to a USB flash memory device using the PDF, TIFF, or JPEG formats.
Returns the LCD to the home screen.
Home
(only on model X642e)
Help Tips
(only on model X642e)
Menu
(only on model X642e)
Contrast icon
(only on model X642e)
Accesses the context-sensitive Help feature.
Accesses the menus. These menus are only available when the MFP is in the
Ready state.
Identifies the location of the contrast wheel. Look on the left side of the MFP near this icon to locate the contrast wheel which adjusts the contrast on the LCD.
Home screen and Home screen buttons
After the MFP is turned on and a short warm-up period occurs, the LCD shows the following basic screen which is referred to as the Home screen. Use the Home screen buttons to initiate an action such as copy, fax, or scan, to open the menu screen, or to respond to messages.
Buttons and touchscreen icon buttons
Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list)
Models X644e,
X646e
Model X642e Button name Function
Copy
Copy Touch to access the Copy menus.
If the home screen is shown, press a number to access the
Copy menus, too.
2-4 Service Manual
7002-xxx
Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list) (continued)
Models X644e,
X646e
Model X642e Button name Function
E-mail Touch to access the E-mail menus. It is possible to scan a document directly to an e-mail address.
(Icon)
(Icon)
(Button)
Ready.
Status/ Supplies
Menus (A key is shown on the button.)
Status message bar
Touch to access the menus. These menus are only available when the MFP is in the
Ready
state.
For models X644e and X646e, the Menus icon is on a gray bar called the navigation bar.
For model X642e, the Menu button is on the left side of the
operator panel. See “Menu (only on model X642e)” on page 2-4 .
Shows the current MFP status such as
Ready
or
Busy
.
Shows MFP conditions such as
Toner Low
.
Shows intervention messages to give instructions on what the user should do so the MFP can continue processing, such as
Close door or insert print cartridge.
Status/Supplies Appears on the LCD whenever the MFP status includes a message requiring intervention. Touch it to access the messages screen for more information on the message including how to clear it.
(Button)
FTP
? (Tips)
FTP
Tips is a context-sensitive Help feature.
For models X644e and X646e, all menus have a Tips icon on the touchscreen panel.
For model X642e, there is a Tips button on the operator
panel, below the touchscreen panel. See “Help Tips (only on model X642e)” on page 2-4 .
Touch to access the File Transfer Protocol (FTP) menus. A document can be scanned directly to an FTP site.
(Icon)
Fax Touch to access the Fax menus.
Fax
(Button)
Release
Held Faxes
Home
Release Held
Faxes (or Held
Faxes if in
Manual Mode)
For models X644e and X646e, touch the Home icon to return to the home screen. The Home icon appears on every screen except the home screen.
For models X642e, press the Home button on the operator panel below the touchscreen to return to the home screen.
See
“Home (only on model X642e)” on page 2-4
.
There are held faxes with a scheduled hold time previously set. To access the list of held faxes, touch this button.
Diagnostic information 2-5
7002-xxx
Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list) (continued)
Models X644e,
X646e
Model X642e Button name Function
Search Held
Jobs
Held Jobs
To search on any of the following items and return any matches:
• User names for held or confidential print jobs
• Job names for held jobs, excluding confidential print jobs
• Profile names
• Bookmark container or job names
• USB container or job names for supported extensions only
To open a screen containing all the held jobs containers.
Held Jobs
Lock Device
Unlock Device
Models X644e and X646e—This button appears on the screen when the MFP is unlocked and Device Lockout
Personal Identification Number (PIN) is not null or empty.
To lock the MFP:
1. Touch Lock Device to open a PIN entry screen.
2. Enter the correct PIN to lock the operator panel which locks both the operator panel buttons and the touchscreen buttons.
Once the operator panel is locked, the PIN entry screen clears, and the Lock Device button is replaced with the
Unlock Device button.
Note: If an invalid PIN is entered, Invalid PIN.
appears. A pop-up screen appears with the Continue button. Touch
Continue . The home screen returns with the Lock Device button.
Models X644e and X646e—This button appears on the screen when the MFP is locked. The operator panel buttons and shortcuts cannot be used while it appears and no default copy starts may occur.
To unlock the MFP:
1. Touch Unlock Device to open a PIN entry screen.
2. Enter the correct PIN to unlock the numeric keypad (0–9) and the Backspace button on the operator panel.
Note: If an invalid PIN is entered, Invalid PIN.
appears. A pop-up screen appears with the Continue button. Touch
Continue. The home screen returns with the Unlock Device button.
2-6 Service Manual
7002-xxx
Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list) (continued)
Models X644e,
X646e
Model X642e Button name Function
Cancel
Jobs
Scan the
ADF
Cancel Jobs
Cancel
Job
Cancel Jobs
Scan the ADF
Scan the flatbed
To open the Cancel Jobs screen. The Cancel Jobs screen shows any of the following items under three headings on the screen which are Print, Fax, and Network:
• print job
• copy job
• fax
• profile
• FTP
• e-mail send
Each heading has its own list of jobs shown in a column under the heading. Each column can only show three jobs per screen. The job appears as a button. If more than three jobs exist in a column, then the down arrow appears at the bottom of the column. Each touch of the down arrow accesses one job in the list. When more than three jobs exist, once the fourth job in the list is reached, then an up arrow appears at the top of the column.
Model X644e and X646e—On the gray navigation bar, these two choices indicate that two types of scanning are possible.
One may choose to scan from the ADF or the flatbed.
Scan the flatbed
Submit
Back
Submit
Back
Back
Down arrow
For models X644e and X646e—To save the value as the new user default setting, touch Submit . A green button indicates a choice. If a different value within a menu item is touched, it needs to be saved to become the current user default setting.
For model X642e—To save the value as the new user default setting, touch Submit .
For all models, touch Back to return to the previous screen, and all the settings for the scan job made on Sample screen one are lost.
Back
For models X644e and X646e, when the
Back button is shaped like this, no other navigation is possible from this screen except to go back. If any other choice is made on the navigation bar, the screen closes.
Back
For models X644e and X646e, when the
Back button is shaped like this, both forward and backward navigation is possible from this screen, so there are other options available on the screen besides selecting Back .
Touch the down arrow to move down to the next item in a list, such as a list of menu items or values. The down arrow does not appear on a screen with a short listing. It only appears if the entire listing cannot be seen on one screen. On the last screen of the listing, the down arrow is gray to indicate that it is not active since the end of the list appears on this screen.
Diagnostic information 2-7
7002-xxx
Buttons and touchscreen icon buttons (refer to Menus & Messages for comprehensive list) (continued)
Models X644e,
X646e
Model X642e Button name Function
Up arrow
Unselected radio button
Touch the up arrow to move up to the next item in a list, such as a list of menu items or values. When on the first screen presented with a long list, the up arrow is gray to indicate that it is not active. On the second screen needed to show the rest of the listed item, the up arrow is blue to show that it is active.
This is an unselected radio button.
Continue
Cancel
Done
Continue
Selected radio button
This is a selected radio button. Touch a radio button to select it. The radio button changes color to show it is selected. In Sample screen two, the only paper size selected is Letter.
Continue Touch Continue after a menu item or value on a screen is selected and more changes need to be made for a job from the original screen. Once Continue is touched, the original screen appears.
Custom Allows for creating a custom button based on the user’s needs.
Custom
Cancel
Cancel Touch Cancel to cancel an action or a selection.
Touch to cancel out of a screen and return to the previous screen.
Done
Select
Done
Touch to select a menu. The next screen appears showing menu items.
Touch to select a menu item. The next screen appears showing values.
Allows specifying that a job is finished. For example, when scanning an original document, one could indicate that the last page is scanned, and then printing the job would begin.
Home Touch the Home button to return to the home screen. The
Home button appears on every screen except the home
screen. See the “Home screen and Home screen buttons” on page 2-4 for more information.
2-8 Service Manual
7002-xxx
Menus
A number of menus are available to make it easy for you to change MFP settings or print reports. To access the menus and settings:
• Models X644e/X646e—touch the menu icon in the lower right corner of the home screen
• Models X642e—press the menu button ( ) to the left of the operator panel.
When a value or setting is selected and saved, it is stored in MFP memory.
Once stored, these settings remain active until new ones are stored or the factory defaults are restored.
Note: Settings chosen for faxing, scanning, e-mailing, copying, and settings for printing from the application may override the settings selected from the operator panel.
The following diagram shows the touch screen menu index and the menus and items available under each menu. For more information about menus and menu items, see the Menus and Messages Guide on the
Software and Documentation CD.
Paper Menu
Default Source
Paper Size/Type
Configure MP
Envelope Enhance
Substitute Size
Paper Texture
Paper Weight
Paper Loading
Custom Types
Custom Names
Custom Bin Name
(only X644e/X646e)
Universal Setup
Bin Setup
(X644e/X646e) only
Reports
Menu Settings Page
Device Statistics
Network Setup Page
Shortcut List
Fax Job Log
Fax Call Log
E-mail Shortcuts
Fax Shortcuts
FTP Shortcuts
Profiles List
NetWare Setup Page
Print Fonts
Print Directory
Manage Shortcuts
Manage Fax Shortcuts
Manage E-mail Shortcuts
Manage FTP Shortcuts
Manage Profile Shortcuts
Network/Ports
TCP/IP
IPv6
E-mail Server Setup
Address Book Setup
(only X644e/X646e)
Wireless
Standard Network
Network <x>
Standard USB
USB <x>
Standard Parallel
(only X644e/X646e)
Parallel <x>
Standard Serial
Serial <x>
NetWare
AppleTalk
LexLink
Settings
General Settings
Copy Settings
Fax Settings
E-mail Settings
FTP Settings
Print Settings
Security
Set Date and Time
Help
Print all guides
Copy guide
E-mail guide
Fax guide
FTP guide
Information guide
Print defects guide
Supplies guide
Diagnostic information 2-9
7002-xxx
Symptom tables
Printer symptoms
Symptom Action
Dead machine
Touchscreen panel blank, LED is on
Go to
“Dead machine service check” on page 2-125
.
Go to
“LCD touchscreen display service check—models
Touchscreen all white
Touchscreen panel blank, LED off, operator panel buttons do not work
Go to
“LCD touchscreen display service check—models
Go to
“Operator panel right cover assembly service check” on page 2-154 .
LCD touchscreen icon buttons do not work Go to
“LCD touchscreen display service check—models
LCD touchscreen (mono—model X642e)— contrast does not change with contrast control
Go to
“LCD touchscreen contrast control service check— model X642e” on page 2-149 .
LCD touchscreen (color—models X644e/
X646e)—unable to change LCD touchscreen backlight
LCD (mono—model X642e)— Home and
Help buttons on operator panel do not operate.
LCD (mono—model X642e)—Menu button on operator panel does not operate.
Go to on page 2-151
Go to
“LCD touchscreen backlight—models X644e/X646e”
“Operator panel Help and Home buttons service check—model X642e” on page 2-154
.
Go to
“Operator panel Menu button service check—model
.
Operator panel—none of the buttons work.
Replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64 .
Operator panel—one button does not work Replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64 .
Operator panel LED does not come on while MFP operates normally
Paper feed problems—printer or integrated
500-sheet paper tray
Paper jams at exit of redrive assembly— duplex option not installed.
Paper jams at exit of redrive assembly— duplex option installed.
Go to
“Operator panel right cover assembly service check” on page 2-154 .
Go to
“Paper feed service check—printer” on page 2-156
.
Go to
Go to
“Paper feed service check—printer” on page 2-156
“Duplex option service check” on page 2-127 .
.
Fuser solenoid fails to operate.
Printer—black page (print quality)
Printer—blank page (print quality)
Printer—light print (print quality)
Printer—background (print quality)
Printer—residual image (print quality)
Printer—skew (print quality)
Printer—banding (print quality)
Printer—random marks (print quality)
Printer—toner on backside of printed page.
(print quality)
Go to “Fuser solenoid service check” on page 2-140 .
Go to
“Print quality—all black page” on page 2-160 .
Go to
“Print quality—blank page” on page 2-161 .
Go to
“Print quality—light print” on page 2-164
.
Go to
“Print quality—background” on page 2-162
.
Go to
“Print quality—residual image” on page 2-163
.
Go to
“Paper feed service check—printer” on page 2-156 .
Go to
“Print quality—banding” on page 2-163 .
Go to
“Print quality—random marks” on page 2-161 .
Go to
“Print quality—toner on backside of printed page” on page 2-164
.
2-10 Service Manual
7002-xxx
Printer symptoms (continued)
Symptom
Printer—vertical black bands on edge of copy (print quality)
Unable to clear a 32-Unsupported Print
Cartridge user error message.
Action
Go to “Print quality—black bands on outer edges of the page” on page 2-163 .
Go to
“Signature button assembly service check” on page 2-170
.
Scanner—ADF symptoms
Symptom Action
ADF does not recognize paper length in the paper tray
ADF does not recognize one or all paper widths of paper in the paper tray
Go to
“ADF paper length sensor service check—models
Go to
“ADF paper width sensor service check—models
Scanner—flatbed symptoms
Symptom
Flatbed scanner does not recognize paper size.
A blue screen on the touchscreen. The
MFP does not come to a Ready state.
A clicking noise coming from the back of the MFP between the scanner and the printing unit.
Action
Go to
“Flatbed size sensor service check” on page 2-131
.
Go to
“843.xx Error code service check” on page 2-116
Go to
“843.xx Error code service check” on page 2-116
Scanner—scan quality
Symptom
Vertical streaks or lines on image
All black or blank page
Wavy lines—flatbed or mixed mode up to
300 dpi
Line compression
Action
Go to
“Vertical streaks or lines on image” on page 2-165
Go to
“All black or blank image” on page 2-168
Go to
Go to
“Line compression” on page 2-169
High-capacity feeder (2000-sheet) symptoms
Symptom
The printer does not recognize the highcapacity feeder installed.
Paper feed problem with the high-capacity feeder.
Action
Go to
“High-capacity feeder input tray service check” on page 2-141
.
Go to
“High-capacity feeder input tray service check” on page 2-141
.
Diagnostic information 2-11
7002-xxx
Paper tray symptoms
Symptom
Paper feed problem with 250-Sheet Paper
Tray.
Paper feed problem with 500-Sheet Paper
Tray.
Media fails to pass through from the lower attached Paper Tray option to the next higher mounted option.
Action
Go to
“Input tray(s) service check” on page 2-147
Go to
“Input tray(s) service check” on page 2-147 .
Go to
“Input tray(s) service check” on page 2-147 .
Duplex option symptoms
Symptom
Paper feed problem with Duplex.
Paper jams at Paper Removal Tray.
Paper skews in the Duplex Option.
Paper fails to pass from lower option through the Duplex Option.
Action
Go to
“Duplex option service check” on page 2-127 .
Go to
“Duplex option service check” on page 2-127 .
Go to
“Duplex option service check” on page 2-127 .
Go to
“Duplex option service check” on page 2-127 .
Envelope feeder symptoms
Symptom Action
Envelopes do not feed from the envelope feeder.
Go to
“Envelope feeder service check” on page 2-129
.
Envelopes do not feed properly into printer. Go to
“Envelope feeder service check” on page 2-129
.
2-12 Service Manual
7002-xxx
Messages and error codes
Service error codes
Service error codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition.
Service error codes are indicated by a three-digit error code followed by a period and additional numbers in the format XXX.YY. In most cases, five digits are shown. Additional sub error codes display if you press and hold
Start ( ) and 2 when an error message is displayed. Not all error conditions have additional sub error information.
Sub error codes for 8xx, 9xx, and 2xx error codes
The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the printer, envelope feeder, and duplex option.
To display sub error codes (where available)
When a 9 xx or 2 xx error displays:
1.
Press and hold Start ( ) and 2 to view for sub error codes.
The first screen of information displays. Write down the information.
2.
Continue pressing Start and 2 until each screen of information is obtained.
3.
When the last screen displays, the original message displays.
Printed error codes
Additional information is available by printing the error log. See “Print Log” on page 3-22
.
Service error codes (8xx.xx)
Error code
Sub codes
Display text
842 .xx
Service Scanner
Description Action
843
845
848
848
.xx
.00
.00
.01
Service Scanner
Service Image
Processing Unit
Modem/Config ID
Mismatch
Modem/Config ID
Mismatch
This error indicates that a scanner communications failure.
This error indicates that a problems has been detected with the flatbed carriage mechanical hardware. It may also indicate interference between the flatbed CCD assembly and a metal bracket.
Go to
“842.xx Error code service check” on page 2-115
.
Go to
“843.xx Error code service check” on page 2-116
.
This error code indicates a failure of the image processing ASIC.
Replace the scanner control card
(SCC). See “Scanner control card removal” on page 4-48 .
There is no modem installed on a modem version of the MFP.
Check to see if a modem card is installed in the MFP. If no modem is installed, install a modem card. If the modem is installed, go to
Error code service check” on page 2-118 .
Modem is present on a no modem version of the MFP.
Remove the modem that has been installed as this MFP does not support a modem.
Diagnostic information 2-13
7002-xxx
Service error codes (9xx.xx)
Error code
Sub codes
Display text
900 .xx
900
901
902
903
904
905
906
910
911
912
913
914
917
.90
.xx
.xx
.xx
.xx
.xx
.xx
.xx
.00
.00
.00
.00
.00
Description Action
RIP Software
947 Modem Init Failed
Engine flash error
Engine software error
Paperport link driver error
Interface violation by
RIP
Interface violation by
Paperport device
RIP interface driver error
DC pick motor acceleration stall
(autocompensator motor).
DC pick motor excessive PWM
DC pick motor underspeed error
DC pick motor overspeed error
DC pick motor no encoder feedback
Problem with transfer— transfer servo start error.
Defective modem hardware.
Indicates that the flash which the system board code is programmed into is bad. Replace the system board.
These errors indicate an unrecoverable system software error.
These errors indicate an unrecoverable system software error.
These errors indicate an unrecoverable system software error.
These errors indicate an unrecoverable system software error.
These errors indicate an unrecoverable system software error.
Go to
“900.xx Error code service check” on page 2-118
.
Replace the modem card.
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Go to “Paper feed service check— printer” on page 2-156 .
• Check autocompensator cable connectors
• Check autocompensator for binds
• Check system board
• Check autocompensator motor
• Check system board
• Check autocompensator
• Check system board
• Check autocompensator
Check autocompensator assembly
Go to “Paper feed service check— printer” on page 2-156
“Paper feed service check— printer” on page 2-156 .
• Check HVPS
• Check system board
• Check HVPS/input sensor/toner sensor cable.
Go to “Paper feed service check— printer” on page 2-156 .
Go to
“Transfer roll service check” on page 2-172
.
2-14 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
920 .01
Hot roll took too long to heat up after transitioning to new enhanced mode
(standby control only.
Fuser page count between 0 and 99,999.
920
920
920
920
.02
.03
.04
.06
Hot roll fell too far below the desired temperature while in standby. Fuser page between 0 and
99,999.
Hot roll too cool when checking for slope change in standby.
Fuser page count between 0 and 99,999.
Hot roll too cool when heating to desired temperature after slope change (standby control only). Fuser page count between 0 and 99,999.
Description
• Bad thermistor, circuit or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
• Low wattage or incorrect lamp.
• Incorrect hot roll.
Action
Go to
“920.xx—Cold fuser service check” on page 2-132
.
• Bad thermistor, circuit or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
• Low wattage or incorrect lamp.
• Incorrect hot roll.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
• Bad thermistor, circuit or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
• Low wattage or incorrect lamp.
• Incorrect hot roll.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
• Bad thermistor, circuit or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
• Low wattage or incorrect lamp.
• Incorrect hot roll.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
• Fuser is not receiving AC power.
• Poor supply line voltage.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
920.
.07
Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count between 0 and 99,999.
Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count between 0 and
99,999.
• Bad thermistor, circuit, or cabling.
• Very noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Abrupt change in temperature that has disrupted control.
• Incorrect hot roll.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
Diagnostic information 2-15
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
920 .11
Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count between
100,000 and 199,999.
920
920
920
920
.12
.13
.14
.16
Hot roll fell too far below the desired temperature while printing. Fuser page count between
100,000 and 199,999.
Hot roll too cool while checking for slope change. Fuser page count between 100,000 and 199,999.
Hot roll too cool when heating to desired temperature after slope change. Fuser page count between 100,000 and 199,999.
Description
• Bad thermistor, circuit, or cabling.
• Very noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Fuser is not receiving AC power.
• Poor supply line voltage.
Action
Go to
“920.xx—Cold fuser service check” on page 2-132
.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
920 .17
Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count between 100,000 and
199,999.
Fuser has been below the desired temperature for too long while the media is in the nip.
Fuser page count between 100,000 and
199,999.
• Bad thermistor, circuit, or cabling.
• Very noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Abrupt change in temperature that has disrupted control.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
2-16 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
920 .21
Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count between
200,000 and 299,999.
920
920
920
920
.22
.23
.24
.26
Hot roll fell too far below the desired temperature while printing. Fuser page count between
200,000 and 299,999.
Hot roll too cool while checking for slope change. Fuser page count between 200,000 and 299,999.
Hot roll too cool when heating to desired temperature after slope change. Fuser page count between 200,000 and 299,999.
Description
• Bad thermistor, circuit, or cabling.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
Action
Go to
Go to
Go to
“920.xx—Cold fuser service check” on page 2-132
.
.
“920.xx—Cold fuser service check” on page 2-132
.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
• Fuser is not receiving AC power.
• Poor supply line voltage.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
920 .27
Fuser is not increasing in temperature even though the lamp has been on for an extended tim. Fuser page count between 200,000 and
299,999.
Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count between 200,000 and 299,999.
• Bad thermistor, circuit, or cabling.
• Very noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Abrupt change in temperature that has disrupted control.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
Diagnostic information 2-17
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
920 .31
Under temperature during steady state control. Fuser page count between 300,000 and 399,999.
920
920
920
920
.32
.33
.34
.36
Hot roll fell too far below desired temperature while printing. Fuser page count between
300,000 and 399,999.
Hot roll too cool while checking for slope change. Fuser page count between 300,000 and 399,999.
Hot roll too cool when heating to desired temperature after slope change. Fuser page count between 300,000 and 399,999.
Description
• Bad thermistor, circuit, or cabling.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
Action
Go to
Go to
Go to
.
.
“920.xx—Cold fuser service check” on page 2-132
.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
• Fuser is not receiving AC power.
• Poor supply line voltage.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
920 .37
Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count between 300,000 and
399,999.
Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count between 300,000 and 399,999.
• Bad thermistor, circuit, or cabling.
• Very noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Abrupt change in temperatures that has disrupted control.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
2-18 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
920 .41
Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count between
400,000 and 499,999.
920
920
920
920
.42
.43
.44
.46
Hot roll fell too far below the desired temperature while printing. Fuser page count between
400,000 and 499,999.
Hot roll too cool while chickens for slope change. Fuser page count between 400,000 and 499,999.
Hot roll too cool when heating to desired temperature after slop change. Fuser page count between 400,000 and 499,999
Description
• Bad thermistor, circuit, or cabling.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
Action
Go to
Go to
Go to
.
.
“920.xx—Cold fuser service check” on page 2-132
.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
• Fuser is not receiving AC power.
• Poor supply line voltage.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
920 .47
Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count between 400,000 and
499,999.
Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count between 400,000 and 499,999.
• Bad thermistor, circuit, or cabling.
• Very noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Abrupt change in temperatures that has disrupted control.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
Diagnostic information 2-19
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
920 .51
Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count more than
500,000.
920
920
920
920
.52
.53
.54
.56
Hot roll fell too far below desired temperature while printing. Fuser page count more than
500,000.
Hot roll too cool while checking for slope change. Fuser page count more than
500,000.
Hot roll too cool when heating to desired temperature after slope change. Fuser page count more than
500,000.
Description
• Bad thermistor, circuit, or cabling.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
Action
Go to
Go to
Go to
.
.
“920.xx—Cold fuser service check” on page 2-132
.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
• Fuser is not receiving AC power.
• Poor supply line voltage.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
920 .57
Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser count more than 500,000.
Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count more than
500,000.
• Bad thermistor, circuit, or cabling.
• Very noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Abrupt change in temperatures that has disrupted control.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
2-20 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
920 .91
Hot roll took too long to heat up after transitioning to new enhanced mode. Fuser page count not available.
920
920
920
920
.92
.93
.94
.96
Hot roll fell too far below desired temperature while printing. Fuser page count not available.
Hot roll too cool while checking for slope change. Fuser page count not available.
Hot roll too cool when heating to desired temperature after slope change. Fuser page count not available.
Description
• Bad thermistor, circuit, or cabling.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
• Bad thermistor, circuit, or cabling.
• Noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Incorrect hot roll.
Action
Go to
“920.xx—Cold fuser service check” on page 2-132
Go to
Go to
Go to
“920.xx—Cold fuser service check” on page 2-132
.
.
.
“920.xx—Cold fuser service check” on page 2-132
.
• Fuser is not receiving AC power.
• Poor supply line voltage.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
920 .97
Fuser is not increasing in temperature even though the lamp has been on for an extended time. Fuser page count not available.
Fuser has been below the desired temperature for too long while media is in the nip. Fuser page count not available.
• Bad thermistor, circuit, or cabling.
• Very noisy thermistor signal.
• Fuser not receiving AC power.
• Poor supply line voltage.
• Excessive load on the fuser.
• Low voltage or incorrect lamp.
• Abrupt change in temperatures that has disrupted control.
Go to
“920.xx—Cold fuser service check” on page 2-132
.
Diagnostic information 2-21
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
922 .02
Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between 0 and 99,999.
922
922
922
922
922
922
.03
.04
.06
.07
.12
.13
Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between 0 and 99,999.
Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between 0 and 99,999.
Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 0 and
99,999.
Fuser has taken too long to reach desired temperature after increasing interrupt gap.
Fuser page count between 0 and 99,999.
Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between
100,000 and 199,999.
Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between
100,000 and 199,999.
Description
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Action
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
2-22 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
922 .14
922
922
922
922
922
922
922
.15
.16
.17
.22
.23
.24
.25
Description Action
Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between
100,000 and 199,999.
After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count between
100,000 and 199,999.
Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 100,000 and 199,999.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
The control code has been lost.
Go to
“922.xx—Cold fuser check” on page 2-134 .
Go to
“922.xx—Cold fuser check” on page 2-134 .
Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count between 100,000 and
199,999.
Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between
200,000 and 299,999.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between
200,000 and 299,999.
Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between
200,000 and 299,999.
After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count between
200,000 and 299,999.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
The control code has been lost.
Go to
“922.xx—Cold fuser check” on page 2-134 .
Go to
“922.xx—Cold fuser check” on page 2-134 .
Diagnostic information 2-23
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
922 .26
922
922
922
922
922
922
922
.27
.32
.33
.34
.35
.36
.37
Description Action
Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 200,000 and 299,999.
Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count between 200,000 and
299,999.
Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between
300,000 and 399,999.
Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between
300,000 and 399,999.
Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between
300,000 and 399,999.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count between
300,000 and 399,999.
Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 300,000 and 399,999.
The control code has been lost.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count between 300,000 and
399,999.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
Go to
“922.xx—Cold fuser check” on page 2-134 .
Go to
“922.xx—Cold fuser check” on page 2-134 .
2-24 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
922 .42
922
922
922
922
922
922
.43
.44
.45
.46
.47
.52
Description Action
Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count between
400,000 and 499,999.
Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count between
400,000 and 499,999.
Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count stopped at
500,000 to preserve data.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count between
400,000 and 499,999.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count between
400,000 and 499,999.
Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count between 400,000 and 499,999.
The control code has been lost.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
Go to
“922.xx—Cold fuser check” on page 2-134 .
Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count between 400,000 and
499,999.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Excessive load on the fuser.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
Diagnostic information 2-25
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
922 .53
922
922
922
922
922
922
.54
.55
.56
.57
.92
.93
Description Action
Hot roll reached final lamp detection temperature but took longer than largest time in lookup table. Fuser page count stopped at
500,000 to preserve data.
Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count stopped at
500,000 to preserve data.
After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count stopped at
500,000 to preserve data.
Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count stopped at
500,000 to preserve data.
The control code has been lost.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
POR the MFP and retry.
If the error message remains, go to
“922.xx—Cold fuser check” on page 2-134 .
Go to
“922.xx—Cold fuser check” on page 2-134 .
Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count stopped at 500,000 to preserve data.
Hot roll took too long to reach the beginning lamp detection temperature. Fuser page count not available.
Hot roll reached ‘final lamp detection temperature’ but took longer than largest time in lookup table. Fuser page count not available.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Excessive load on the fuser.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
2-26 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
922 .94
922
922
922
923
923
923
923
923
.95
.96
.97
.01
.11
.21
.31
.41
Description Action
Hot roll timed out in trying to reach the final lamp detection temperature. Fuser page count not available.
After hot roll lamp detection, did not roll over to steady state control in time. Fuser page count not available.
Hot roll did not reach operating temperature in time (new enhanced control). Fuser page count not available.
Fuser has taken too long to reach desired temperature after increasing interpage gap. Fuser page count not available.
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Control code has been lost.
Go to
“922.xx—Cold fuser check” on page 2-134 .
POR and retry.
If the error message remains, go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Bad thermistor, circuit, or cabling.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
• Low wattage or incorrect lamp.
• Excessive load on the fuser.
• Fuser not receiving sufficient AC power.
• Poor supply line voltage.
Go to
“922.xx—Cold fuser check” on page 2-134 .
Fuser over temperature.
Fuser page count between 0 and 99,999.
Go to
“923.xx—Hot fuser service check” on page 2-135
.
Fuser over temperature.
Fuser page count between 100,000 and
199,999.
• Short in the thermistor circuit.
• Noisy thermistor signal
• Fuser is actually overheating due to hardware faults.
• Short in the thermistor circuit.
• Noisy thermistor signal
• Fuser is actually overheating due to hardware faults.
Go to
“923.xx—Hot fuser service check” on page 2-135
.
Fuser over temperature.
Fuser page count between 200,000 and
299,999.
Go to
“923.xx—Hot fuser service check” on page 2-135
.
Fuser over temperature.
Fuser page count between 300,000 and
399,999.
Fuser over temperature.
Fuser page count between 400,000 and
499,999.
• Short in the thermistor circuit.
• Noisy thermistor signal
• Fuser is actually overheating due to hardware faults.
• Short in the thermistor circuit.
• Noisy thermistor signal
• Fuser is actually overheating due to hardware faults.
• Short in the thermistor circuit.
• Noisy thermistor signal
• Fuser is actually overheating due to hardware faults.
Go to
Go to
.
“923.xx—Hot fuser service check” on page 2-135
.
Diagnostic information 2-27
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
923 .51
923
924
924
924
924
924
924
924
925
925
.91
.01
.11
.21
.31
.41
.51
.91
.01
.02
Description
Fuser over temperature.
Fuser page count stopped at 500,000 to preserve data.
Fuser over temperature.
Fuser page count not available.
Open thermistor check failure. Fuser page count between 0 and
99,999.
Open thermistor check failure. Fuser page count between 100,000 and 199,999.
Open thermistor check failure. Fuser page count between 200,000 and 299,999.
Open thermistor check failure. Fuser page count between 300,000 and 399,999.
Open thermistor check failure. Fuser page count between 400,000 and 499,999.
Open thermistor check failure. Fuser page count over 500,000.
Open thermistor check failure. Fuser page count not available.
• Short in the thermistor circuit.
• Noisy thermistor signal
• Fuser is actually overheating due to hardware faults.
• Short in the thermistor circuit.
• Noisy thermistor signal
• Fuser is actually overheating due to hardware faults.
• Noisy thermistor signal.
• Intermittent connection.
• Thermistor cable not connected or thermistor actually open.
• Noisy thermistor signal.
• Intermittent connection.
• Thermistor cable not connected or thermistor actually open.
• Noisy thermistor signal.
• Intermittent connection.
• Thermistor cable not connected or thermistor actually open.
• Noisy thermistor signal.
• Intermittent connection.
• Thermistor cable not connected or thermistor actually open.
• Noisy thermistor signal.
• Intermittent connection.
• Thermistor cable not connected or thermistor actually open.
• Noisy thermistor signal.
• Intermittent connection.
• Thermistor cable not connected or thermistor actually open.
• Noisy thermistor signal.
• Intermittent connection.
• Thermistor cable not connected or thermistor actually open.
• 115 V lamp in 220 V printer.
• Lamp has excessive wattage.
Lamp detection performed and found error. Fuser page count between 0 and 99,999.
Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected.
Fuser page count between 0 and 99,999.
Attempting to POR machine after receiving a 925.01.
Action
Go to
“923.xx—Hot fuser service check” on page 2-135
.
Go to
“923.xx—Hot fuser service check” on page 2-135
.
Go to
“924.xx—Hot fuser service check” on page 2-136
.
Go to
“924.xx—Hot fuser service check” on page 2-136
.
Go to
“924.xx—Hot fuser service check” on page 2-136
.
Go to
“924.xx—Hot fuser service check” on page 2-136
.
Go to
“924.xx—Hot fuser service check” on page 2-136
.
Go to
“924.xx—Hot fuser service check” on page 2-136
.
Go to
“924.xx—Hot fuser service check” on page 2-136
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
2-28 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
925 .11
925
925
925
925
925
925
925
925
.12
.21
.22
.31
.32
.41
.42
.51
Description
Lamp detection performed and found error. Fuser page count between 100,000 and
199,999.
Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected.
Fuser page count between 100,000 and
199,999.
• 115 V lamp in 220 V printer.
• Lamp has excessive wattage.
Attempting to POR machine after receiving a 925.01.
Lamp detection performed and found error. Fuser page count between 200,000 and
299,999.
Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected.
Fuser page count between 200,000 and
299,999.
Lamp detection performed and found error. Fuser page count between 300,000 and
399,999.
• 115 V lamp in 220 V printer.
• Lamp has excessive wattage.
Attempting to POR machine after receiving a 925.01.
• 115 V lamp in 220 V printer.
• Lamp has excessive wattage.
Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected.
Fuser page count between 300,000 and
399,999.
Lamp detection performed and found error. Fuser page count between 400,000 and
499,999.
Attempting to POR machine after receiving a 925.01.
• 115 V lamp in 220 V printer.
• Lamp has excessive wattage.
Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected.
Fuser page count between 400,000 and
499,999.
Lamp detection performed and found error. Fuser page count stopped at 500,000 to preserve data.
Attempting to POR machine after receiving a 925.01.
• 115 V lamp in 220 V printer.
• Lamp has excessive wattage.
Action
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Go to
“925.xx—Hot fuser service check” on page 2-137
.
Diagnostic information 2-29
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
925 .52
925
925
927
927
927
927
927
927
927
.91
.92
.00
.01
.02
.03
.04
.05
.06
Description Action
Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected.
Fuser page count stopped at 500,000 to preserve data.
Lamp detection performed and found error. Writes to the fuser information chip have been disabled due to a previous write failure.
Attempting to POR machine after receiving a 925.01.
• 115 V lamp in 220 V printer.
• Lamp has excessive wattage.
Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected.
Writes to the fuser information chip have been disabled due to a previous write failure.
Service fan error.
Attempting to POR machine after receiving a 925.01.
Main fan stalled.
Cartridge fan stalled.
Main fan took too long to ramp up.
Main fan underspeed or stalled during speed adjustment state.
Go to
Go to
Go to
.
.
“925.xx—Hot fuser service check” on page 2-137
.
• Loose connector.
• External blockage of the fan, preventing it from turning.
• Bad fan.
Go to
“Main fan service check” on page 2-119 .
• External blockage of fan
• Fan may not turn due to internal fan problem.
Go to
“Main fan service check” on page 2-119 .
Go to
“Cartridge fan service check” on page 2-119
.
• Loose connector.
• External blockage of the fan, preventing it from turning.
• Bad fan.
• Loose connector.
• External blockage of the fan, preventing it from turning.
• Bad fan.
• Corrupted feedback signal.
• Fan input voltage may be too low.
Go to
Go to
“Main fan service check” on page 2-119 .
Main fan overspeed during speed adjustment state.
• Corrupted feedback signal.
• Fan input voltage may be too low.
Main fan capture data is invalid and speed control is at maximum in fan control idle state.
Corrupted or non-existent feedback signal.
Go to
“Main fan service check” on page 2-119 .
Go to
“Main fan service check” on page 2-119 .
2-30 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
927 .07
929
929
929
930
932
933
934
936
936
936
936
936
.00
.66
.67
.00
.00
.00
.00
.00
.10
.11
.20
.21
Description
Main fan capture data is invalid and speed control is at maximum in fan control adjustment state.
Corrupted feedback signal.
Toner sensor error—a problem has been detected with the toner sensor.
• Check the toner sensor
• Check cable
• Check system board
An error has been detected. No home windows has been detected.
No toner sensor transition.
• Check toner cartridge.
• Check toner sensor
• Check toner sensor
• Check toner cartridge
Check the printhead An incorrect printhead has been detected
Printhead lost HSYNC.
Mirror motor locked, no first HSYNC received.
Mirror motor lost lock
Mirror moor not up to speed
No hall effect detected at motor start. Motor is type 0.
No hall effect detected at motor start. Motor is type 1.
Failed to stop within timeout, motor is type 0.
Failed to stop within timeout, motor is type 1.
• Check printhead
• Check cables and connections
• Check system board
• Check printhead
• Check cables and connectors
• Check system board.
• Check printhead
• Check cables and connections
• Check system board
• Check printhead
• Check system board
• Check cable connections
• Defective motor
• Severe gear blinds in gearbox assembly
• System board
• Check cable connections
• Defective motor
• Severe gear binds in gearbox assembly.
• System board
• Defective motor
• Defective system board
• Defective motor
• Defective system board
Action
Go to “Main fan service check” on page 2-119 .
Go to
“Toner sensor service check” on page 2-171
.
Go to
“Toner sensor service check” on page 2-171
.
Go to
“Toner sensor service check” on page 2-171
.
Go to “Printhead service check” on page 2-165 .
Go to “Printhead service check” on page 2-165 .
Go to “Printhead service check” on page 2-165 .
Go to “Printhead service check” on page 2-165 .
Go to “Printhead service check” on page 2-165 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Diagnostic information 2-31
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
936 .30
No lock detected at motor start for motor ID.
Motor is type 0.
936
936
936
936
936
937
.31
.60
.61
.9
.91
.4
No lock detected at motor start for motor ID.
Motor is type 1.
No lock detected at normal motor start.
Motor is type 0.
No lock detected at normal motor start.
Motor is type 1.
Stall detected during speed control. Motor is type 0.
Stall detected during speed control. Motor is type 1.
Description
• Check for paper jams
• Gear binds
• Defective motor
• Check motor cable and connections
• Check for paper jams
• Gear binds
• Defective motor
• Check motor cable and connections
• Check for paper jams
• Gear binds
• Defective motor
• Check motor cable and connections
• Check for paper jams
• Gear binds
• Defective motor.
• Defective motor cable
• Cable connections
• Defective cable
• Check cable connections
• Defective motor
• Paper jams
• Defective cable
• Check cable connections
• Defective motor
• Paper jams
• Faulty motor sensor
• Faulty system board
937
937
937
937
.41
.5
.51
.7
Overspeed detected during speed control.
Motor is type 0.
Overspeed detected during speed control.
Motor is type 1.
Overspeed detected during position control.
Motor is type 0.
Overspeed detected during position control.
Motor is type 1.
Loss of lock detected by higher level code. Motor is type 0.
• Faulty motor sensor
• Faulty system board
• Faulty motor sensor
• Faulty system board
• Faulty motor sensor
• Faulty system board
• Defective motor cable
• Defective main drive motor
• Paper jams
Action
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
2-32 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
937 .71
937
939
.80
.00
Description
Loss of lock detected by higher level code. Motor is type 1.
Driver over temperature detection. Motor is type 0.
RIP–engine communications lost.
• Defective motor cable
• Defective main drive motor
• Paper jams
• Excessive gear loading in gearbox assembly
System board
940
947
948
949 .00
950
.00
.00
.00
.00
Action
Go to
“Main drive service check” on page 2-153 .
Go to
“Main drive service check” on page 2-153 .
LVPS zero-crossing test failed.
• Incorrect LVPS installed
• Noisy AC power source
• LVPS to system board cable loose
PQET RAM test incomplete,
PQET RAM test did not complete,
PQET RAM test failed
MARCH0
PQET RAM test failed
MARCH1
PQET RAM test busy failure
Pel clock check failed
PQET failed to pass RAM tests on the system board
System board
Delay line calibration failure
NVRAM mismatch
System board
POR the printer several times, if the error code continues to be displayed, replace the system board. See
“System board and inner shield removal —models
.
Check to make sure the correct
LVPS assembly has been installed.
If the correct supply is installed, check to make sure the LVPS to system board cable is installed correctly. If correct, replace the
LVPS assembly. See
“Low voltage power supply removal” on page 4-109 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Go to
EPROM mismatch failure” on page 2-120 . or go to
“950.30 through 950.60 EPROM mismatch failure” on page 2-121 .
Diagnostic information 2-33
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
951 .00
Description Action
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Warning: When replacing any one of the following components:
• Flatbed interconnect card
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a
POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components. Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
2-34 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
950 .30—
.60
Service NVRAM mismatch
952 .00
953 .00
NV failure:n
Description
EPROM mismatch failure
CRC error has occurred. This is recoverable.
Action
This error code indicates a mismatch between the System
Board assembly and the interface card assembly.
Warning: In the event of replacement of any one of the following components:
• Flatbed interconnect card
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a
POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components. Once a component has been installed in a machine, it cannot be used in another machine.
It must be returned to the manufacturer.
Go to
EPROM mismatch failure” on page 2-121 .
Perform POR to clear the error.
Replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64 .
Diagnostic information 2-35
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
954 .00
Description
955
956
957
958
.00
.00
.00
.00
Code CRC
System board
System board
Nand failure
Action
CRC failure or ECC code failure on the system board.
This error indicates a system board processor failure.
This error indicates a system board processor failure.
Replace the interface card. See
“Interface card assembly removal” on page 4-107
.
Warning: When replacing any one of the following components:
• Flatbed interconnect card
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a
POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components. Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
Printer has performed more than
100 “shift and replace” operations as a result of EC bit corrections.
Replace the system board. See
“System board and inner shield removal —models X644e/X646e” on page 4-131 .
2-36 Service Manual
7002-xxx
Service error codes (9xx.xx) (continued)
Error code
Sub codes
Display text
980 .00
981
982
983
984
990
.00
.xx
.00
.00
.00
Unreliable communications to
Paperport device
Interface protocol violation by engine
Paperport communication error
Invalid command received by device
Invalid command parameter received by device
General device equipment check
991 .00
Device system card failed basic assurance test
Description
Indicates an equipment check condition has occurred in the specified device, but the device is unable to identify the exact component failure.
The specified device has detected an equipment check in its system card.
Action
The engine is experiencing unreliable communications to the specified device.
The engine protocol violation detected by the specified device.
Communications error detected by the specified device.
Invalid command received by the specified device.
Invalid command parameter received by the specified device.
Service errors 980 thru 984
< device > can be one of the following: system board, duplex, tray x (1, 2, 3, 4, or 5), envelope feeder or output bin.
Service errors 980 thru 984
< device > can be one of the following: system board, duplex, tray x (1, 2, 3, 4, or 5), envelope feeder or output bin.
Diagnostic information 2-37
7002-xxx
User status displays.
User status displays
Code
Sub code
Display text Description/action
Bin [x] Full x represents the number of the output bin that is full when the MFP bins are linked.
Remove print media from the bins. The message clears once the output level of the linked bins is no longer full.
Busy
The MFP is busy receiving, processing, or printing data.
Press Stop to access the job queue.
Deleting selected job(s)
Flushing Buffer
Hex Trace
The Delete button is touched after jobs have been selected.
The MFP flushes corrupted data and discards the current print job.
The MFP is in Hex Trace mode.
Hex Trace isolates the source of a print job problem. When Hex Trace is active, all data sent to the MFP prints in hexadecimal and character representation.
Exit Hex Trace to print jobs normally. To exit Hex Trace, unplug the MFP.
Insufficient resources. Try again when the system is idle.
Invalid or incorrect password.
There are not enough system resources at this time.
Try again after the current job is complete.
An incorrect password is entered.
Touch Continue to return to the screen to enter a correct password.
Invalid PIN.
An incorrect Personal Identification Number (PIN) is entered.
Touch Continue to return to the screen to enter a correct PIN.
Job cannot be deleted
A job in the job list is touched, but it cannot be canceled.
Maintenance
The MFP maintenance counter has exceeded its limit, so the MFP requires maintenance.
Replace the maintenance items. If necessary, reset the MFP maintenance counter.
Network
Network [x]
Network [x], [y]
A network interface is the active communication link.
Wait for the message to clear.
Notes:
• The current interface appears on the Menu Settings Page. Interfaces shown without an x or y means the active host interface is a standard interface.
• x indicates the active interface is connected to the MFP through PCI connector x .
• x , y indicates the active interface is connected to the MFP through channel y on PCI connector x , or that x equals 0 on the standard network interface.
No jobs selected
The Delete button is touched when no jobs are selected.
2-38 Service Manual
7002-xxx
User status displays (continued)
Code
Sub code
Display text Description/action
Parallel
Parallel [x]
A parallel interface is the active communication link.
Notes:
• The current interface appears on the Menu Settings Page. Interfaces shown without an x or y means the active host interface is a standard interface.
• x indicates the active interface is connected to the MFP through PCI connector x .
• x , y indicates the active interface is connected to the MFP through channel y on PCI connector x , or that x equals 0 on the standard network interface.
Serial [x]
A serial interface is the active communication link.
Notes:
• The current interface appears on the Menu Settings Page. Interfaces shown without an x or y means the active host interface is a standard interface.
• x indicates the active interface is connected to the MFP through PCI connector x .
• x , y indicates the active interface is connected to the MFP through channel y on PCI connector x , or that x equals 0 on the standard network interface.
USB
USB [x]
[PJL RDYMSG]
Power Saver
The MFP is processing data through the specified USB port.
This is the Printer Job Language (PJL) Ready message.
The MFP is ready to receive and process data. It is reducing its electricity consumption while idle. If the MFP remains inactive for the period of time specified in the Power Saver menu item (60 minutes is the factory default), the
Power Saver
message replaces the
Ready
message.
Send a job to print.
Press any operator panel button.
Printing
Printing page [x]
The MFP is printing a job.
A sheet of print media moves through the MFP to be printed.
x represents the number of the sheet being printed. Even though a duplex
(two-sided) sheet has two sides, called pages, it only counts as one sheet.
Printing page [x], copy [a] / [b]
A sheet of print media moves through the MFP to be printed.
x represents the number of the sheet being printed. Even though a duplex sheet has two sides, called pages, it only counts as one sheet. So, pages are not counted, only sheets passing through the MFP.
The total number of sheets in a set is not known, but the number of sets is known. For example, a user may have requested that three copies print, so there are three sets of sheets, but the number of sheets is unknown.
Printing page [x]/[y], copy [a]/[b]
A sheet of print media moves through the MFP to be printed.
x represents the number of the sheet being printed. A sheet is considered a front and back page of one piece of print media. A group of sheets is called a set. y represents the total number of sheets in a set. a is the number of the current set printing. b is the total number of sets to be printed. For example, a user may send a 6-page duplex print job and select three copies to print. So, there are three sheets to print for each job. This makes one set. Three sets must print before the user has the complete job.
Diagnostic information 2-39
7002-xxx
User status displays (continued)
Code
Sub code
Display text Description/action
Ready
Scanner automatic document feeder cover open
Standard Bin Ful
Bin [x] Full
[bin name] Full
The automatic document feeder (ADF) cover is open.
Close the cover.
The standard bin is full.
x represents the number of the bin that is full.
[ bin name ] specifies a previously defined name for the bin, such as Mary’s bin, and it is full.
Remove the stack of print media from the standard output bin or from the specified bin to clear the message.
System busy, preparing resources for job.
Not all resources needed for the job are available.
Wait for the message to clear.
System busy, preparing resources for job.
Deleting held job(s).
Not all resources needed for the job are available. Some held jobs are deleted to free system memory.
Wait for the message to clear.
Toner Low
The toner cartridge is low on toner.
The Menu Settings Page shows the level. It takes an unspecified amount of time for the MFP to read the level of toner. Until the level is read, the MFP does not show the message.
• The message clears automatically when the cover or door over the toner cartridge is opened or if the MFP power is turned off and then on.
• Replace the toner cartridge. If it is not replaced, the MFP issues the message again when the door or cover is closed.
Tray [x] Empty
The MFP is ready to receive and process jobs.
Print, fax, scan, e-mail, copy, or use FTP.
x represents the number of the tray. The tray has no print media installed.
1. Remove the tray. The message clears.
2. Install print media in the tray according to the User’s Guide .
3. Insert the tray.
Tray [x] Low x specifies the number of the tray that is low.
Load print media into the specified tray to clear the message.
Tray [x] Missing x represents the number of the tray missing from the MFP.
The message is on the Menu Settings Page also.
Insert the tray to clear the message.
If the Tray 1 Missing message does not clear when tray 1 is inserted, go to
“Parallel port service check” on page 2-159 . If Tray 2 through 5 Missing
message does not clear by inserting the tray, go to “Input tray(s) service check” on page 2-147
.
Waiting
The MFP receives a page of data to print but waits for an End of Job command, a Form Feed command, or additional data.
Press Stop . Touch Continue to print the contents of the buffer.
Cancel the current job.
Wait for the message to clear.
Fax status displays
Answering
The MFP is answering a fax call.
2-40 Service Manual
7002-xxx
User status displays (continued)
Code
Sub code
Display text Description/action
Call complete
Connect <x>bps
Dialing
A fax call is completed.
The fax is connected. < x > is the baud rate per second.
A fax number is dialed. If the number is too long to fit on the screen only the word
Dialing
appears.
Fax failed
Job stored for delayed transmission.
Line busy
No answer
No dial tone
Queued for sending
The fax failed to send.
The scanning completes for a delayed send fax job.
A fax number is dialed, but the fax line is busy.
A fax number is dialed, but no connection is made.
The MFP does not have a dial tone.
The scanning process of a fax job completed, but it is not sent yet because another fax job is being sent or received. As this one job waits for its turn, this message appears for three seconds.
Receive complete
Receiving page [n]
The MFP has received an entire fax job.
The MFP receives page [ received.
n ] of the fax job, where n is the number of the page
Sending page [n]
The MFP sends page [ sent.
n ] of the fax job, where n is the number of the page
Set clock
The Real Time Clock is not set. This message appears if no other fax status message appears. It remains until the clock is set.
Set the clock.
Waiting for redial
The MFP is waiting to redial the fax number.
Diagnostic information 2-41
7002-xxx
User attendance messages
User attendance messages
Code
Sub code
Primary message Description/action
Change Cartridge
Invalid Refill
Select one of the following actions:
Remove the toner cartridge and install a new cartridge.
Change [src] to
[Custom String]
Lets the user override the current print media source for the remainder of the print job. The formatted page prints as is on the print media installed in the tray. This may cause clipping of text or images.
Touch Use current [src] to ignore the message and print on the print media loaded in the tray.
Touch Continue :
• which continues the job if the correct size and type are loaded in the tray, and this size and type are specified in the Paper Menu using the operator panel.
• which is ignored if there is no print media in the tray.
Touch Cancel job to cancel the current job if needed.
Change <src> to
<Custom Type Name>
New print media is required to finish a print job.
Load the indicated source with the requested size and type of print media.
Touch Continue to print with print media currently in the tray.
Change [src] to [size]
Lets the user override the current print media source for the remainder of the print job. The formatted page prints as is on the print media installed in the tray. This may cause clipping of text or images.
Touch Use current [src] to ignore the message and print on the print media loaded in the tray.
Touch Continue :
• which continues the job if the correct size and type are loaded in the tray, and this size and type are specified in the Paper Menu using the operator panel.
• which is ignored if there is no print media in the tray.
Touch Cancel job to cancel the current job if needed.
Change [src] to [size]
[type]
Lets the user override the current print media source for the remainder of the print job. The formatted page prints as is on the print media installed in the tray. This may cause clipping of text or images.
Touch Use current [src] to ignore the message and print on the print media loaded in the tray.
Touch Continue :
• which continues the job if the correct size and type are loaded in the tray, and this size and type are specified in the Paper Menu using the operator panel.
• which is ignored if there is no print media in the tray.
Touch Cancel job to cancel the current job if needed.
2-42 Service Manual
7002-xxx
User attendance messages (continued)
Code
Sub code
Primary message Description/action
Check Duplex
Connection
This messages displays for the following conditions:
• The duplex option may have been removed from the printer, possibly to clear a paper jam or to remove the option.
• The duplex option may be attached to the printer but a communications problem may prevent the printer from detection. For example, there may be a poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not connected properly, reattach or reconnect it.
• Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on).
Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem, turn the printer off and on. If the message continues to be displayed, go to
“Duplex option service check” on page 2-127
.
Check Tray x
Connection
Tray x =Tray 2, Tray 3, Tray 4, or Tray 5
This messages displays for the following conditions:
• The specified device may have been removed from the printer, possibly to clear a paper jam or to uninstall the option.
• The option may be attached to the printer but a communications problem may prevent the printer from detecting the option. For example, there may be a poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not connected properly, reattach or reconnect it.
• Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on).
Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem, turn the printer off and on. If the message continues to be displayed, go to
“Input tray(s) service check” on page 2-147
.
Clean scanner backing strip
During a scanner calibration, the firmware detects that the scanner backing strip for the backside of scan jobs may be dirty.
Touch Cancel Job if a scan job is processing when the attendance message appears. This cancels the job and clears the message.
Touch Scan from Automatic Document Feeder if the page jam recovery is active. Scanning resumes from the ADF immediately after the last successfully scanned page.
Touch Scan from flatbed if page jam recovery is active. Scanning resumes from the flatbed immediately after the last successfully scanned page.
Touch Finish job without further scanning if page jam recovery is active.
The job ends at the last successfully scanned page, but the job is not canceled. Successfully scanned pages go to their destination: copy, fax, email, or FTP.
Touch Restart job if job recovery is active and the job can be restarted. The message clears. A new scan job containing the same parameters as the previous job starts.
Diagnostic information 2-43
7002-xxx
User attendance messages (continued)
Code
Sub code
Primary message Description/action
Clean scanner glass
Disk corrupted
Disk Full – Scan Job
Canceled
Insert Cartridge or
Close Door
Insert tray [x]
Install Bin x or Cancel Job
During a scanner calibration, the firmware detects that the scanner ADF or flatbed glass may be dirty.
Touch Cancel Job if a scan job is processing when the attendance message appears. This cancels the job and clears the message.
Touch Scan from Automatic Document Feeder if the page jam recovery is active. Scanning resumes from the ADF immediately after the last successfully scanned page.
Touch Scan from flatbed if page jam recovery is active. Scanning resumes from the flatbed immediately after the last successfully scanned page.
Touch Finish job without further scanning if page jam recovery is active.
The job ends at the last successfully scanned page, but the job is not canceled. Successfully scanned pages go to their destination: copy, fax, email, or FTP.
Touch Restart job if job recovery is active and the job can be restarted. The message clears. A new scan job containing the same parameters as the previous job starts.
Model X646e only. Occurs when the MFP attempts a hard disk recovery on a corrupted hard disk, and the hard disk cannot be repaired. The hard disk must be reformatted.
Touch Reformat disk to reformat the hard disk and clear the message.
Warning: All files stored on the hard disk are deleted.
Model X646e only. The scan job cancels or stops due to insufficient hard disk space.
Note: The scanner finishes scanning currently committed pages in the ADF, but data is lost when the job cancels itself.
Touch Continue to clear the message.
This message displays when the printer front door is open or the print cartridge is missing.
Occurs when the MFP detects a missing tray. x can be 1, 2, 3, 4, or 5.
Insert the specified tray to clear the message.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
If the message cannot be cleared, go to “Paper size sensing service check” on page 2-158
or
“Input tray(s) service check” on page 2-147 .
Bin x =Bin 1, Bin 2, or Bin 3.
This message is displayed when a paper handling option has been hot unplugged. The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed.
The following actions may be taken:
• Install the option.
• Select one of the following:
- Cancel Job
- Reset Printer
- Reset Active Bin
If the message cannot be cleared, go to “Input tray(s) service check” on page 2-147 .
2-44 Service Manual
7002-xxx
User attendance messages (continued)
Code
Sub code
Primary message Description/action
Install Duplex or Cancel Job
Install envelope feeder
Install tray [x]
Load manual feeder with [Custom String]
This message is displayed when a duplex option has been hot unplugged.
The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed.
The following actions may be taken:
• Install the duplex option.
• Select one of the following:
- Cancel Job
- Reset Printer
- Reset Active Bin
If the message cannot be cleared, go to
“Duplex option service check” on page 2-127 .
The MFP detects that the optional envelope feeder is missing between the time the job processes, but before the job prints. Sometime during processing, the optional envelope feeder is removed.
Install the optional envelope feeder. The message clears.
Touch Cancel Job if needed.
Touch Reset Active Bin to reset the active bin for a linked set of bins.
If the message cannot be cleared, go to
“Envelope feeder service check” on page 2-129 .
The MFP detects that optional Tray [ x ], where x is the number of the tray, is missing while the job processes, but before the job prints. Sometime during processing, the optional tray is removed.
Install the optional tray specified by x . The message clears.
Touch Cancel Job if needed.
Touch Reset Active Bin to reset the active bin for a linked set of bins.
If the message cannot be cleared, go to “Input tray(s) service check” on page 2-147 .
Occurs when the MFP receives a manual feed request that a specific print media be loaded into the multipurpose feeder. The print media is previously defined as a custom string which appears on the operator panel.
Touch Continue .
• If print media is in the multipurpose feeder, the job continues to print.
• If there is no print media in the multipurpose feeder, all requests for additional pages are automatically overridden, and print media is selected from an automatic source.
Touch Automatically select media to override manual requests for
Manual
Paper and
Manual Env
for the rest of the print job. All requests for additional pages are automatically overridden, and print media is selected from an automatic source.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Diagnostic information 2-45
7002-xxx
User attendance messages (continued)
Code
Sub code
Primary message Description/action
Load manual feeder with [Custom Type
Name]
Load manual feeder with [size]
Load manual feeder with [type] [size]
Load [src] with
[Custom String]
Load [src] with
[Custom Type Name]
Occurs when the MFP receives a manual feed request that specific print media be loaded into the multipurpose feeder. The print media is previously defined as a custom type from Custom 1 through Custom 6. The custom type name appears on the operator panel.
Touch Continue .
• If print media is in the multipurpose feeder, the job continues to print.
• If there is no print media in the multipurpose feeder, all requests for additional pages are automatically overridden, and print media is selected from an automatic source.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Occurs when the MFP receives a manual feed request for a specific size of print media when none is loaded into the multipurpose feeder.
Feed a sheet of print media into the multipurpose feeder to clear the message and continue the job.
Touch Continue if print media is in the multipurpose feeder. The job continues.
Touch Continue if there is no print media in the multipurpose feeder. All requests for additional pages are automatically overridden, and print media is selected from an automatic source.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Occurs when the MFP receives a manual feed request for a specific size and type of print media when none is loaded into the multipurpose feeder.
Touch Continue if print media is in the multipurpose feeder. The job continues.
Touch Continue if there is no print media in the multipurpose feeder. All requests for additional pages are automatically overridden, and print media is selected from an automatic source.
Touch Automatically select media to override manual requests for
Manual
Paper and
Manual Env
for the rest of the print job. All requests for additional pages are automatically overridden and print media is selected from an automatic source.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Occurs when a source is loaded with an incorrect print media size and type as specified in the Paper Menu.
Touch Continue . Load the specified source that is set for the requested size and type.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Occurs when a source is loaded with an incorrect print media size and type as specified in the Paper Menu.
Touch Continue . Load the specified source that is set for the requested size and type.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
2-46 Service Manual
7002-xxx
User attendance messages (continued)
Code
Sub code
Primary message Description/action
Load [src] with [size]
Occurs when a source is loaded with an incorrect print media size as specified in the Paper Menu.
Touch Continue . Load the specified source that is set for the requested size.
Touch Automatically select media to override manual requests for
Manual
Paper
and
Manual Env
for the rest of the print job. All requests for additional pages are automatically overridden, and print media is selected from an automatic source.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Load [src] with [type]
[size]
Occurs when the MFP requests that a specific media source be loaded with a specific type and size as specified in the Paper Menu, but the current source contains an incorrect media size and type.
Touch Continue . Load the specified source that is set for the requested size and type.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Reattach envelope feeder
The MFP detects that the optional envelope feeder is missing between the time the job processes, and when it prints. Sometime during processing, the optional envelope feeder is removed.
Touch Cancel Job to clear the message and continue without using the optional envelope feeder.
Install the optional envelope feeder.
Reattach
Bins x–y
Bins x–y =Bins 1 to 5, Bins 2 to 6, or Bins 6 to 10
This messages displays for the following conditions:
• The specified output bins may have been removed from the printer, possibly to clear a paper jam or to remove the option.
• The option(s) may be attached to the printer but a communications problem may prevent the printer from detecting the option. For example, there may be a poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not connected properly, reattach or reconnect it.
• Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on).
Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem, turn the printer off and on. If the message continues to be displayed, go to
“Input tray(s) service check” on page 2-147
.
Diagnostic information 2-47
7002-xxx
User attendance messages (continued)
Code
Sub code
Primary message Description/action
Reattach
Envelope Feeder
Reattach
Output Bin x
Remove paper from standard output bin
This messages displays for the following conditions:
• The feeder may have been removed from the printer, possibly to clear a paper jam or to remove the option.
• The feeder may be attached to the printer but a communications problem may prevent the printer from detecting the option. For example, there may be a poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not connected properly, reattach or reconnect it.
• Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on).
Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem, turn the printer off and on. If the message continues to be displayed, go to
“Envelope feeder service check” on page 2-129
.
Bin x =Bin 1, Bin 2, or Bin 3
This messages displays for the following conditions:
• The specified output bin may have been removed from the printer, possibly to clear a paper jam or to remove the option.
• The option may be attached to the printer but a communications problem may prevent the printer from detecting the option. For example, there may be a poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not connected properly, reattach or reconnect it.
• Accept the configuration change which notifies the printer the option has been hot unplugged (removed with the power on).
Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem, turn the printer off and on.
The standard output bin is full of print media.
Remove the stack of print media from the bin to clear the message and resume printing.
Touch Continue to make the MFP recheck the output level in the standard output bin.
2-48 Service Manual
7002-xxx
User attendance messages (continued)
Code
Sub code
Primary message Description/action
Replace all originals if restarting job.
One or more messages which interrupted a scan job are now cleared.
Replace the original documents in the scanner to restart the scan job.
Touch Cancel Job if a scan job is processing when the attendance message appears. This cancels the job and clears the message.
Touch Scan from Automatic Document Feeder if the page jam recovery is active. Scanning resumes from the ADF immediately after the last successfully scanned page.
Touch Scan from flatbed if page jam recovery is active. Scanning resumes from the flatbed immediately after the last successfully scanned page.
Touch Finish job without further scanning if page jam recovery is active.
The job ends at the last successfully scanned page, but the job is not canceled. Successfully scanned pages go to their destination: copy, fax, email or FTP.
Touch Restart job if job recovery is active and the job can be restarted. The message clears. A new scan job containing the same parameters as the previous job starts.
Replace wiper
The MFP detects that the fuser wiper needs replacing.
1. Replace the fuser wiper.
2. Touch Continue to clear the message.
Touch Ignore to clear the message, but at the next power-on, the message appears again.
Restore held jobs?
Model X646e only. Held jobs are found on the hard disk after a power-on reset of the MFP.
Touch Yes to restore the held jobs to the hard disk and make them available. The jobs data remains on the hard disk; however, the job control information is stored in the MFP memory. Touch Quit to stop restoring held jobs before all jobs are restored. Unrestored jobs remain on the hard disk and are retrievable again only at the next power-on reset.
Note: A pop-up screen appears to indicate Restoring held jobs(s) xxx/yyy, where xxx indicates the number of the current job being restored, and yyy is the total number of jobs to be restored.
Touch Do not restore to have the held jobs remain on the hard disk until they are deleted.
Scan Document Too Long
The scan job exceeds the maximum number of pages.
Note: The scanner finishes scanning current pages in the ADF, but data is lost when the job cancels itself after reaching the maximum number of pages.
Touch Continue to clear the message.
Touch Cancel Job to clear the message if the job can be restarted.
Touch Restart job if the job can be restarted. The message clears, and a new scan job containing the same parameters as the previous job starts.
Scanner ADF Cover Open
The scanner automatic document feed cover is open.
The message clears when the cover is closed.
Scanner Jam Access
Cover Open
The scanner jam access cover is open.
Close the cover to clear the message.
Scanner registration successfully completed
Scanner registration is successful.
Touch Continue to clear the message.
Diagnostic information 2-49
7002-xxx
User attendance messages (continued)
Code
Sub code
Primary message Description/action
30
31
31
32
32
34
35
36
.xx
.00
.xx
.00
.xx
.xx
.xx
.xx
Some held jobs were lost
Model X646e only. Occurs when the MFP tries to restore all jobs on a hard disk regardless of the number of held jobs not restored. The message appears once.
Touch Continue to clear the message.
Some held jobs are not restored. They stay on the hard disk and are inaccessible.
Invalid refill, change cartridge
Defective cartridge
Defective Print
Cartridge
Error code 31 displays when the top front cover is closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective. Depending on the setting of the
Machine Class ID the printer may be allowed to print pages during this 10-
20 second interval. If pages are allowed to print, they are not reprinted once a good print cartridge is inserted.
Note : This error indicates the printer was able to read the cartridge ID, but the ID did not pass the verification test. To pass the verification test, the ID read from the print cartridge must match the ID from the last “good” print cartridge or the same ID must be read from the print cartridge twice. The last “good” print cartridge ID is stored in NVRAM.
Unsupported cartridge
Unsupported cartridge installed. Replace cartridge.
Unsupported Print
Cartridge
• Smart chip cabling loose on controller card. Reseat smart chip cabling inside printer.
• Replace cartridge.
Error 32 displays when the top cover is closed and an unsupported print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the setting of the Machine
Class ID the printer may be allowed to print pages during this 10-20 second interval. If pages are allowed to print, then they are not reprinted once a good print cartridge is inserted. If this does not fix the problem, go to
“Signature button assembly service check” on page 2-170 .
Short paper
The MFP detects a refilled Lexmark Cartridge Return Program print cartridge.
Install a new print cartridge to clear the message.
The length of the print media is too short to print the formatted data.
Touch Continue to clear the message and continue printing. The MFP does not automatically reprint the page that prompted the message.
Make sure the Paper Size setting in the Paper Menu is correct for the size of print media used. If MP Feeder Size is set to Universal, make sure the print media is large enough for the formatted data.
Touch Cancel Job to cancel the current job if needed.
Insufficient memory to support Resource Save feature
The MFP lacks the memory needed to enable Resource Save. This message usually indicates too much memory is allocated for one or more of the MFP link buffers.
Touch Continue to disable Resource Save and continue printing.
Install additional memory.
Resolution Reduced
The resolution of the page has been reduced from 600 dpi to 300 dpi to prevent a Memory Full error. This message can only occur if the Resolution
Reduction setting is turned on.
Note: 1200 dpi pages are not resolution reduced. If a 1200 dpi job runs out of memory, a Memory Full error displays.
2-50 Service Manual
7002-xxx
User attendance messages (continued)
Code
Sub code
37 .xx
Primary message
37
37
37
38
39
.xx
.xx
.xx
.xx
.xx
Description/action
Insufficient memory for Flash Memory
Defragment operation
The MFP cannot defragment flash memory because the memory used to store undeleted flash resources is full.
Touch Continue to clear the message.
To perform the defragment operation, install additional memory, or delete fonts, macros, and other data to free some memory space.
Touch Reset Active Bin to change to another linked bin.
Insufficient memory to collate job
The MFP cannot collate the job because the memory is full.
Touch Continue to print the pages processed before the memory became full. Some memory frees up, so collating begins for the remainder of the print job.
For example, if a 50-page print job is sent, and 10 copies are requested, and the MFP runs out of memory at page 30, pages 1–30 would collate and print 10 copies. The MFP would then print and collate pages 31–50 and print 10 copies of these pages.
Insufficient memory, some held jobs were lost
Model X646e only. The MFP depletes its memory while it attempts to restore held jobs. The message appears once.
Some held jobs are not restored. They stay on the hard disk and are inaccessible.
Insufficient memory, some Held Jobs were lost
Held jobs are deleted in order to process the current job.
The message appears once per job.
Touch Continue to clear the message and continue printing.
To avoid this error in the future for other jobs, install more memory.
Touch Cancel Job to cancel the current job if needed.
Memory full
The MFP is processing data, but the memory used to store pages is full.
To avoid this error in the future:
Simplify the print job by reducing the amount of text or graphics on a page and deleting unnecessary downloaded fonts or macros.
Install additional memory.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Page is too complex to print
The page may not print correctly because the print information on the page is too complex.
To avoid this error in the future:
Reduce the complexity of the page by reducing the amount of text or graphics on the page and deleting unnecessary downloaded fonts or macros.
Set Page Protect to On in the Setup Menu in the Settings menu.
Install additional memory.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Diagnostic information 2-51
7002-xxx
User attendance messages (continued)
Code
Sub code
42 .
xy
Primary message
Printer/cartridge mismatch
Description/action
Cartridge region code does not match MFP region code. x =printer region and y =cartridge region. The following regions may be listed:
50
51
52
53
54
.
xx
.xx
.xx
.xx
.xx
Code Region
2
3
0
1
4
9
Worldwide
USA and Canada
Europe, Middle East, and Africa
Asia
Latin America
Undefined region
PPDS font error
Defective flash detected
Not enough free space in flash memory for resources
There is not enough space in the flash memory to store the data currently being downloaded.
Touch Continue to clear the message and continue the print job.
Install flash memory with more storage capacity.
Download the data.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
Unformatted flash detected
The MFP detects a defective flash memory during power-on or during flash format and write operations.
Touch Continue to clear the message and continue printing the current job.
At power-on reset, touch Continue to clear the message and the MFP continues with normal operations except for flash operations.
Install different flash memory to be able to download any resources to flash.
The MFP detects unformatted flash memory.
Touch Continue to clear the message and continue printing. The MFP continues with normal operations except for flash operations.
Reformat the flash to allow flash operations.
If the error message reappears, the flash memory may be defective and require replacing.
Network [x] software error
The MFP has received a request for a font that is not installed when formatting PPDS print data.
Touch Continue to clear the message and continue printing the current job.
Touch Cancel Job to cancel the current job if needed.
Touch Reset Active Bin to change to another linked bin.
The MFP cannot establish communications with a specified installed network port. x indicates the number of the specified port.
• Touch Continue to clear the message and continue printing. The job may not print correctly.
• The MFP disables attempts to communicate through the network interface. No data may be sent or received.
• Reset the MFP.
• Program new firmware for the network interface.
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7002-xxx
User attendance messages (continued)
Code
Sub code
54 .xx
Primary message
54
55
56
56
56
56
57
.xx
.xx
.xx
.xx
.xx
.xx
.xx
Description/action
Serial option [x] error
The MFP detects a serial error, such as framing, parity, or overrun on the specified optional serial port. x is the number of the optional serial port.
• Make sure the serial link is set up correctly, and the appropriate cable is in use.
• Make sure the serial interface parameters (protocol, baud, parity, and data bits) are set correctly on the printer and host computer.
• Touch Continue to clear the message and continue processing the print job; however the print job may not print correctly.
• Turn the MFP off and then on to reset it.
Standard network software error
The MFP firmware detects an installed network port, but cannot establish communication with it.
• Touch Continue to clear the message and continue printing. The job may not print correctly.
• The MFP disables attempts to communicate through the network interface. No data may be sent or received.
• Reset the MFP.
• Program new firmware for the network interface.
Unsupported option in slot [x]
The MFP detects an unsupported option in the specified slot. x indicates the number of the specified slot.
1. Turn the MFP off.
2. Unplug the power cord from the wall outlet.
3. Remove the unsupported option.
4. Connect the power cord to a properly grounded outlet.
5. Turn the MFP on.
Parallel port [x] disabled
A status request occurs over the parallel port, but the parallel port is disabled.
Touch Continue . The MFP discards any data received on the parallel port.
Touch Reset Active Bin to reset the active bin for a linked set of bins.
Serial port [x] disabled
The MFP receives data across a serial port, but the port is disabled.
Touch Continue . The MFP discards any data received on the serial port.
Touch Reset Active Bin to change to another linked bin.
Standard USB port disabled
The MFP receives data through a USB port, but the USB port is disabled.
Touch Continue . The printer discards any data received through the USB port.
Make sure the USB Buffer menu item is not set to Disabled.
Touch Reset Active Bin to change to another linked bin.
USB port [x] disabled
The MFP receives data through a specified USB port, but this USB port is disabled. x is the number of the USB port.
Touch Continue . The MFP discards any data received through the specified USB port.
Make sure the USB Buffer menu item is not set to Disabled.
Touch Reset Active Bin to change to another linked bin.
Configuration change, some held jobs were lost
Model X646e only. The MFP fails to restore held jobs due to configuration changes. The message appears once.
Some held jobs are not restored. They stay on the hard disk and are inaccessible.
Diagnostic information 2-53
7002-xxx
User attendance messages (continued)
Code
Sub code
58
Primary message
58
58
59
59
59
61
.xx
.xx
.xx
.xx
.xx
Description/action
Too many disks installed
Model X646e only. The MFP detects an excess of hard disks installed.
1. Turn the MFP off.
2. Unplug the power cord from the wall outlet.
3. Remove the excess hard disks.
4. Connect the power cord to a properly grounded outlet.
5. Turn the MFP on.
Too many flash options installed
The MFP detects an excess of optional flash memory cards installed.
Touch Continue to clear the message and ignore the extra optional flash memory cards.
The message occurs again unless the excess optional flash memory cards are removed.
1. Turn the MFP off.
2. Unplug the power cord from the wall outlet.
3. Remove the excess flash memory.
4. Connect the power cord to a properly grounded outlet.
5. Turn the MFP on.
Too many trays attached
The MFP detects that too many optional drawers and their matching trays are installed.
1. Turn the MFP off.
2. Unplug the power cord from the wall outlet.
3. Remove the additional drawers.
4. Connect the power cord to a properly grounded outlet.
5. Turn the MFP on.
Incompatible duplex
An unsupported optional duplex unit is attached to the MFP.
Remove the optional duplex unit.
The MFP ceases normal functions until the optional duplex unit is removed.
Touch Continue to clear the message once the optional duplex unit is removed.
Incompatible envelope feeder
An unsupported optional envelope feeder is attached to the MFP.
Remove the optional envelope feeder.
The MFP ceases normal functions until the optional envelope feeder is removed.
Touch Continue to clear the message once the optional envelope feeder is removed.
Incompatible tray [x]
An unsupported optional drawer and its matching tray are attached to the
MFP.
Remove the optional drawer.
The MFP ceases normal functions until the optional drawer is removed.
Touch Continue to clear the message once the optional drawer is removed.
Remove defective disk
Model X646e only. The MFP detects a defective hard disk.
1. Turn the MFP off.
2. Unplug the power cord from the wall outlet.
3. Remove the defective hard disk.
4. Install a new hard disk.
5. Connect the power cord to a properly grounded outlet.
6. Turn the MFP on.
2-54 Service Manual
7002-xxx
User attendance messages (continued)
Code
Sub code
Primary message Description/action
62
63
64
80
81
88
.xx
.xx
.xx
.xx
.xx
.xx
Disk full
Unformatted disk
Unsupported disk format
Model X646e. The hard disk format is not supported.
Format the hard disk prior to performing operations that require the hard disk.
If the message remains, the hard disk may be defective and require replacing.
Scheduled maintenance advised
Service is required to maintain printer performance.
Replace the maintenance items and if necessary, reset the printer maintenance counter. For more information, go to
“Scheduled maintenance” on page 6-1
.
Engine Code CRC
Failure
This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check. POR the MFP to clear the message. The microcode data is discarded and must be re-transmitted from the host computer.
Toner is low
Model X646e only. The hard disk is not formatted.
Format the hard disk prior to performing operations that require the hard disk.
If the message remains, the hard disk may be defective and require replacing.
The toner cartridge is running low on toner.
Replace the toner cartridge if the toner low alarm sounds.
Touch Continue to clear the message if the toner low alarm does not sound.
1565 1565
Emul error, load emulation option
Model X646e only. The MFP detects that there is not enough memory or space on the hard disk to store the data of the print job.
Touch Continue to clear the message and continue processing the current print job. Any information not previously stored on the hard disk is deleted.
• Delete fonts, macros, and other data stored on the hard disk.
• Install a hard disk with a larger memory capacity.
The download emulator contained in the firmware card does not function with the MFP firmware.
Note: The MFP automatically clears the message in 30 seconds and then disables the download emulator on the firmware card.
For help downloading the correct download emulator version, contact the place where you bought your printer.
Diagnostic information 2-55
7002-xxx
User line 2 link messages
If the printer is locked on a particular link, the link indication displays. If the printer is ready to process any link, no messages display. Link messages are listed in the following table.
User message
Parallel
Serial
Serial x
Network x
LocalTalk x
Infrared
Infrared x
Explanation
Standard Parallel Port, if available.
Standard Serial Port, if available.
Serial Port is attached to PCI connector x , where x =1, 2, or 3.
Network card x is attached to PCI connector x, where x =1, 2, or 3.
LocalTalk Card x is attached to PCI connector x, where x =1, 2, or 3.
Standard Infrared port, if available.
Infrared Port x is attached to PCI connector x , x =1, 2, or 3.
Check device connection messages
The messages in the following table display when the printer loses communications with one of the following devices.
User status message
Check Env Feeder
Connection
Check Tray x
Connection
Check Duplex
Connection
Explanation
Check envelope feeder connection.
Check tray x , where x =1, 2, 3, 4, or 5.
Check duplex option connection.
The messages in the following table can occur in two ways. The specified device could have been removed from the printer, for instance to clear a paper jam. Otherwise, the device can still be attached to the printer, but is experiencing a communications problem, not fully connected, or having a hardware failure.
If the device is temporarily removed or not connected properly, then the user is advised to reattach it. When the option is recognized, the printer automatically clears the error and continues. If the option is experiencing a hardware problem, turn the printer off and back on. If the error occurs again, the user is advised to turn the printer off, remove the option, and call for service.
User status message Explanation
Turn Printer OFF to
Enable Option
A printer option, Input Tray, or Envelope Feeder has been attached while the printer is powered on. To use the option, the printer must first be powered off and back on again. Data loss results if print jobs are active when the printer is power cycled. If a print job is active, then remove the option and finish the job. The printer automatically clears the message once the option is removed. Once the job is complete, turn off the printer and attach the option again.
Insert Duplex Front
Cover
The duplex front access cover is not installed.
Close Duplex Rear Door The duplex rear door is open.
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User attendance messages—paper jams and paper handling errors (2xx.xx)
When the printer jams, the appropriate jam message will be displayed on the printer operator panel. If you select
Show Areas
on the operator panel, you can view one or more images to help you clear the jam.
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
200 .00
Description Possible causes Action
200
200
200
200
.01
.02
.04
.06
Paper jam around input sensor.
Input sensor covered too long.
Input sensor covered too long.
Input sensor covered too quickly
Imaged page not expected page.
• Multi-sheet feed that is shingled.
• Tray size sensing wrong size
• Paper jam leaving page over sensor
• Multi-sheet feed that is shingled.
• Tray size sensing wrong size.
• Paper jam leaving page over sensor.
• Multi-sheet feed that is shingled.
• Tray size sensing wrong size.
• Paper jam leaving page over sensor.
• Paper pre-staged in paper path.
• Wrong configuration ID causes engine to assume 500-sheet paper path on 250-sheet model.
• Bouncy input sensor.
Bouncy pass thru sensor.
• Fan media and stack flat in tray or multipurpose feeder.
• Check for anything in the paper path that might cause the paper to jam.
• If clearing a paper jam does not fix the problem, go to
“Input sensor service check” on page 2-146
.
• Fan media and stack flat in tray or MPF.
• Check for anything in the paper path that might cause the paper to jam.
• Check cartridge for obstructions.
• If clearing a paper jam does not fix the problem, go to
“Input sensor service check” on page 2-146
.
• Fan media and stack flat in tray or MPF.
• Check for anything in the paper path that might cause the paper to jam.
• Check cartridge for obstructions.
• If clearing a paper jam does not fix the problem, go to
“Input sensor service check” on page 2-146
.
• Check MPF and friction pad.
• Fan media and stack flat in tray or MPF.
• Use different media.
• Check config ID.
Perform a sensor test to check the sensor for the tray. See
“Sensor Test (input tray)” on page 3-14
.
Diagnostic information 2-57
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
200 .07
Description Possible causes
200
200
200
200
200
200
200
200
.08
.09
.10
.11
.12
.13
.14
.15
Action
Option tray never picked a page.
Fail to feed from option. Possible causes may include media edge locking, worn or contaminated pick tires, stacking tray beyond recommended fill line.
• Fan media and stack flat in tray or MPF.
• Turn media over.
• Reduce amount of media loaded to fill line.
• Replace pick tires.
Go to
“Input sensor service check” on page 2-146
.
Input sensor covered too quickly
• Paper pre-staged in path.
• Bouncy input sensor.
• Check MPF and friction pad.
• Fan media and stack flat in tray or MPF.
• Use different media.
Did not receive proper motor feedback to start laser servo.
Printhead motor not locked when page crosses input sensor
Printhead motor fell out of lock after page arrives at input sensor
Motor connections
• Printhead lock signal not working.
• Printhead control not working.
• Paper pre-staged in path.
• Lock signal went away.
Check the main drive motor cable connections.
If no problem is found with
motor connections, go to “Main drive service check” on page 2-153 .
• Check printhead to system card connections.
• Check printhead motor system.
Go to “Printhead service check” on page 2-165 .
• Check printhead to system card connections.
• Check printhead motor system.
Go to “Printhead service check” on page 2-165 .
Timeout while waiting for laser power adjustment.
Input sensor covered during warm-up sequence.
Page still covering input sensor.
Gap too small • Paper pre-staged in path.
• Bouncy input sensor.
Remove cartridge and make sure input sensor is not covered and is in upright position.
Go to
“Input sensor service check” on page 2-146
.
• Check MFP mechanism and friction pad.
• Fan media and stack flat in tray or MPF.
• Use different media.
Laser power did not settle
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7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
200 .16
Description Possible causes
200
201
201
201
201
.32
.00
.01
.02
.03
Action
Main drive motor error possibly due to mechanical load.
Detected cover switch bounce.
Page did not reach exit sensor. Fuser page count between 0 and
99,999.
Main drive motor not working.
High mechanical load due to paper jam or bind.
• Upper cover not fully closed.
• Cover switch not functioning correctly.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
Main motor identification failed.
Main drive motor identification failed.
Fuser page count between 0 and 99,999.
Main motor not working.
Page did not reach exit sensor. Fuser page count between 0 and
99,999.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
• Make sure paper path is clear
• Check motor to system card connections.
• Replace transport motor.
Go to
“Main drive service check” on page 2-153
.
Check cover switch for proper function.
Go to
“Cover closed switch/ cable service check—printer” on page 2-125 .
• Check fuser entry guide for toner build up.
• Check fuser for wear or contamination. If problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Check motor connections to motor and system board. If no problem is found, go to
“Main drive service check” on page 2-153 .
• Check fuser entry guide for toner build up.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• If no problem with wear or contamination is found, go to
“Fuser exit sensor service check” on page 2-138
Video never started with page two inches past the input sensor. Fuser page count between 0 and 99,999.
Diagnostic information 2-59
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
201 .04
Description Possible causes
Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between 0 and 99,999.
• Page did not enter or exit fuser nip cleanly.
• Narrow media sensor not functioning correctly.
• Actual page is narrow when wide page was expected.
Action
201
201
201
.10
.11
.12
Page did not reach exit sensor. Fuser page count between 100,000 and 199,999.
Main drive motor identification failed.
Fuser page count between 100,000 and
199,999.
Page did not reach exit sensor. Fuser page count between 100,000 and 199,999.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
Main drive motor not working.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
• If label media, ensure front edge meets 1/16 inch requirement.
• Check the fuser for wear or contamination. If found, replace the fuser assembly.
See
“Fuser assembly removal” on page 4-79
.
• If media is narrow, then turn off first sheet detection (In
Diagnostics Menu,
PRINTER SETUP, Engine
Settings 3. Select 16 and touch Submit ).
• The fuser narrow media sensor may not be operating properly. Go to
“Fuser narrow media sensor service check” on page 2-139
.
• Check fuser entry guide for toner build up.
• Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• Check motor to system board connections.
• Replace the main drive motor.
“Main drive assembly removal” on page 4-113
.
• Check fuser entry guide for toner build up.
• Check fuser for wear or contamination. if a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning correctly.
Go to
“Fuser exit sensor service check” on page 2-138
.
201 .13
Video never started with page two inches past the input sensor. Fuser page count between
100,000 and 199,999.
2-60 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
201 .14
Description Possible causes
201
201
201
201
.20
.21
.22
.23
Action
Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between
100,000 and 199,999.
Page did not reach exit sensor. Fuser page count between 200,000 and 299,999.
Main drive motor identification failed.
Fuser page count between 200,000 and
299,999.
Page did not reach exit sensor. Fuser page count between 200,000 and 299,999.
• Page did not enter or exit fuser nip cleanly.
• Narrow media sensor not functioning correctly.
• Actual page is narrow when wide page was expected.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
Main drive motor not working.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
• If label media, ensure front edge meets 1/8 inch requirement.
• Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• If media is narrow, then turn off first sheet detection (In
Diagnostics Menu,
PRINTER SETUP, Engine
Settings 3. Select 16 and touch Submit ).
• The fuser narrow media sensor may not be operating properly. Go to
“Fuser narrow media sensor service check” on page 2-139
.
• Check fuser entry guide for toner build up.
• Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Check motor connections to motor and system board. If no problem is found, go to
“Main drive service check” on page 2-153 .
• Check fuser entry guide for toner build up.
• Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Video never started with page two inches past the input sensor. Fuser page count between
200,000 and 299,999.
Diagnostic information 2-61
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
201 .24
Description Possible causes
201
201
201
201
.30
.31
.32
.33
Action
Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between
200,000 and 299,999
Page did not reach exit sensor. Fuser page count between 300,000 and 399,999
Main drive motor identification failed.
Fuser page count between 300,000 and
399,999.
Page did not reach exit sensor. Fuser page count between 300,000 and 399,999.
• Page did not enter or exit fuser nip cleanly.
• Narrow media sensor not functioning correctly.
• Actual page is narrow when wide page was expected.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
Main drive motor not working.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
• If label media, ensure front edge meets 1/8 inch requirement.
• Check fuser for wear or contamination. If problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• If media is narrow, then turn off first sheet detection (In
Diagnostics Menu,
PRINTER SETUP, Engine
Settings 3. Select 16 and touch Submit ).
• The fuser narrow media sensor may not be functioning properly. Go to
“Fuser narrow media sensor service check” on page 2-139
.
• Check the fuser entry guide for toner build up.
• Check fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Check the motor connections to motor and system board. If no problem is found, go to
“Main drive service check” on page 2-153 .
• Check the fuser entry guide for toner build up.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Video never started with page two inches past the input sensor. Fuser page count betwee
300,000 and 399,999.
2-62 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
201 .34
Description Possible causes
201
201
201
201
.40
.41
.42
.43
Action
Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between
300,000 and 399,999.
Page did not reach exit sensor. Fuser page count between 400,000 and 499,999.
Main drive motor identification failed.
Fuser page count between 400,000 and
499,999.
Page did not reach exit sensor. Fuser page count between 400,000 and 499,999.
• Page did not enter or exit fuser nip cleanly.
• Narrow media sensor not functioning correctly.
• Actual page is narrow when wide page was expected.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
Main drive motor not working.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
• If label media, ensure front edge meets 1/8 inch requirement.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• If media is narrow, then turn off first sheet detection (In
Diagnostics Menu,
PRINTER SETUP, Engine
Settings 3. Select 16 and touch Submit ).
• The fuser narrow media sensor may not be functioning properly. Go to
“Fuser narrow media sensor service check” on page 2-139
.
• Check fuser entry guide for toner build up.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Check the motor connections to motor and system board. If no problem is found, go to
“Main drive service check” on page 2-153 .
• Check the fuser entry guide for toner build up.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Video never started with page two inches past the input sensor. Fuser page count between
400,000 and 499,999.
Diagnostic information 2-63
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
201 .44
Description Possible causes
201
201
201
201
.50
.51
.52
.53
Action
Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count between
400,000 and 499,999.
Page did not reach exit sensor. Fuser page count more than
500,000.
Main drive motor identification failed.
Fuser page count more than 500,000.
Page did not reach exit sensor. Fuser page count more than
500,000.
• Page did not enter or exit fuser nip cleanly.
• Narrow media sensor not functioning correctly.
• Actual page is narrow when wide page was expected.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
Main drive motor not working.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor is not functioning correctly.
• If label media, ensure front edge meets 1/8 inch requirement.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• If media is narrow, then turn off first sheet detection (In
Diagnostics Menu,
PRINTER SETUP, Engine
Settings 3. Select 16 and touch Submit ).
• The fuser narrow media sensor may not be functioning properly. Go to
“Fuser narrow media sensor service check” on page 2-139
.
• Check the fuser entry guide for toner build up.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Check the connections to the motor and system board. If not problem is found, go to
“Main drive service check” on page 2-153 .
• Check the fuser entry guide for toner build up.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Video never started two inches past the input sensor. Fuser pager count more than
500,000.
2-64 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
201 .54
Description Possible causes
201
201
201
201
.90
.91
.92
.93
Action
Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count stopped at
500,000 to preserve data.
Page did not reach exit sensor. Fuser page count is not available.
Main drive motor identification failed.
Fuser page count is not available.
Page did not reach exit sensor. Fuser page count is not available.
• Page did not enter or exit fuser nip cleanly.
• Narrow media sensor not functioning correctly.
• Actual page is narrow when wide page was expected.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
Main drive motor not working.
• Page jammed on fuser input guide.
• Page did not enter or exit fuser nip cleanly.
• Exit sensor not functioning correctly.
• If label media, ensure front edge meets 1/8 inch requirement.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• If media is narrow, then turn off first sheet detection (In
Diagnostics Menu,
PRINTER SETUP, Engine
Settings 3. Select 16 and touch Submit ).
• The fuser narrow media sensor may not be functioning properly. Go to
“Fuser narrow media sensor service check” on page 2-139
.
• Check the fuser entry guide for toner build up.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Check the connections to the motor and system board. If not problem is found, go to
“Main drive service check” on page 2-153 .
• Check the fuser entry guide for toner build up.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Video never started two inches past the input sensor. Fuser page count is not available.
Diagnostic information 2-65
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
201 .94
Description Possible causes
Expected wide page not detected by narrow media sensor, possible accordion jam. Fuser page count is not available.
• Page did not enter or exit fuser nip cleanly.
• Narrow media sensor not functioning correctly.
• Actual page is narrow when wide page was expected.
Action
202 .00
Paper jam at fuser exit or redrive area. Fuser page count between 0 and 99,999.
Page may be jammed in fuser exit or redrive area.
• If label media, ensure front edge meets 1/8 inch requirement.
• Check the fuser for wear or contamination. If a problem is found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• If media is narrow, then turn off first sheet detection (In
Diagnostics Menu,
PRINTER SETUP, Engine
Settings 3. Select 16 and touch Submit ).
• The fuser narrow media sensor may not be functioning properly. Go to
“Fuser narrow media sensor service check” on page 2-139
.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output option(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
2-66 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .01
Description Possible causes
202
202
.02
.03
Action
Page did not cleanly exit fuser or redrive area.
Fuser page count between 0 and 99,999.
Exit sensor covered too long. Fuser page count between 0 and 99,999.
Page may be jammed in fuser exit or redrive area.
Page may be jammed in fuser exit or redrive area.
Page is covering narrow media sensor during warm up. Fuser page count between 0 and
99,999.
If page is not visible from front or rear of machine, partial piece of page may be torn off in fuser covering narrow media sensor. Narrow media sensor or flag may be dislodged/damaged.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output option(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output option(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
Check the fuser for any signs of a piece of media stuck in the fuser.
If the problem recurs, go to
“202.03 Error code service check” on page 2-95 .
Diagnostic information 2-67
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .04
Description Possible causes
202
202
202
202
202
202
.05
.06
.07
.08
.09
.10
Action
Exit sensor bounced.
Fuser page count between 0 and 99,999.
Never sent the divert command to the stacker.
Fuser page count between 0 and 99,999.
Exit sensor assembly.
Go to
“Fuser exit sensor service check” on page 2-138 .
Page is covering exit sensor during warm up.
Fuser page count between 0 and 99,999.
Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
If the problem recurs, go to
“202.06 Error code service check” on page 2-95 .
Timeout waiting for the page ahead. Fuser page count between 0 and
99,999.
Divert media command issued too soon. Fuser page count between 0 and 99,999.
Virtual page timed out waiting for last page of job to be safe in the stapler accumulator.
Fuser page count between
Paper jam around fuser or redrive area. Fuser page count between
100,000 and 199,999.
Page may be jammed in fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
2-68 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .11
Description Possible causes
202
202
.12
.13
Action
Page did not cleanly exit fuser or redrive area.
Fuser page count between 100,000 and
199,999.
Exit sensor covered too long. Fuser page count between 100,000 and
199,999.
Page is covering narrow media sensor during warm up. Fuser page count between 100,000 and 199,999.
Page may be jammed in fuser exit or redrive area.
Page may be jammed in fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• If page is not visible from front or rear of the machine, partial piece may be torn off in the fuser covering the narrow media sensor.
• The narrow media sensor or flag may be dislodged or damaged.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Diagnostic information 2-69
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .14
Description Possible causes
202
202
202
202
202
202
.15
.16
.17
.18
.19
.20
Action
Exit sensor bounced.
Fuser page count between 100,000 and
199,999.
Never sent the divert command to the stacker.
Fuser page count between 100,000 and
199,999.
Exit sensor assembly.
Go to
“Fuser exit sensor service check” on page 2-138 .
Page is covering exit sensor during warm up.
Fuser page count between 100,000 and
199,999.
Timeout waiting for the page ahead. Fuser page count between 100,000 and 199,999.
Divert media command issued too soon. Fuser page count between
100,000 and 199,999.
Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Virtual page timed out waiting for the last page of the job to be safe in the stapler accumulator.
Fuser page count between 100,000 and
199,999.
Paper jam around fuser exit or redrive area.
Fuser page count between 200,000 and
299,999.
Paper may be jammed in fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
2-70 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .21
Description Possible causes
202
202
.22
.23
Action
Page did not cleanly exit fuser or redrive area.
Fuser page count between 200,000 and
299,999.
Exit sensor covered too long. Fuser page count between 200,000 and
299,999.
Page is covering narrow media sensor during warm up. Fuser page count between 200,000 and 299,999.
Page may be jammed in fuser exit or redrive area.
Page may be jammed in fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• If page is not visible from front or rear of the printer, a partial piece of page may be torn off in the fuser covering the narrow media sensor.
• The narrow media sensor or flag may be dislodged or damaged.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Diagnostic information 2-71
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .24
Description Possible causes
202
202
202
202
202
202
.25
.26
.27
.28
.29
.30
Exit sensor may have bounced. Fuser page count between 200,000 and 299,999.
Never sent the divert command to the stacker.
Fuser page count between 200,000 and
299,999.
Exit sensor assembly
Page is covering the exit sensor during warm up.
Fuser page count between 200,000 and
299,999.
Something is keeping the exit sensor covered. A page may not have been cleared from a prior jam.
Timeout waiting for the page ahead. Fuser page counter between
200,000 and 299,999.
Divert media command issued too soon. Fuser page count between
200,000 and 299,999.
Virtual page timed out waiting for last page of job to be safe in the stapler accumulator.
Fuser page count between 200,000 and
299,999.
Paper jam around the fuser exit or redrive area. Fuser page count between 300,000 and
399,999.
Page may be jammed in fuser exit or redrive area.
Action
Go to
“Fuser exit sensor service check” on page 2-138 .
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
2-72 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .31
Description Possible causes
202
202
.32
.33
Action
Page did not cleanly exit fuser or redrive area.
Fuser page count between 300,000 and
399,999.
Exit sensor covered too long. Fuser page count between 300,000 and
399,999.
Page is covering the narrow media sensor during warm up. Fuser page count between
300,000 and 399,999.
Page may be jammed in fuser exit or redrive area.
Page may be jammed in fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• If page is not visible from front or rear of the printer, a partial piece of a page may be torn off in the fuser covering the narrow media sensor.
• The narrow media sensor or flag may be dislodged or damaged.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Diagnostic information 2-73
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .34
Description Possible causes
202
202
202
202
202
202
.35
.36
.37
.38
.39
.40
Exit sensor may have bounced. Fuser page count between 300,000 and 399,999.
Never sent the divert command to the stacker.
Fuser page count between 300,000 and
399,999.
Exit sensor assembly.
Page is covering the exit sensor during warm up.
Fuser page count between 300,000 and
399,999.
Something is keeping the exit sensor covered. A page may not have been cleared from a prior jam.
Timeout waiting for the page ahead. Fuser page count between 300,000 and 399,999.
Divert media command issued too soon. Fuser page count between
300,000 and 399,999.
Virtual page timed out waiting for last page of job to be safe in the stapler accumulator.
Fuser page count between 300,000 and
399,999.
Paper jam around the fuser exit or redrive area. Fuser page count between 400,000 and
499,999.
Page may be jammed in fuser exit or redrive.
Action
Go to
“Fuser exit sensor service check” on page 2-138 .
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
2-74 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .41
Description Possible causes
202
202
.42
.43
Action
Page did not cleanly exit fuser or redrive area.
Fuser page count between 400,000 and
499,999.
Exit sensor covered too long. Fuser page count between 400,000 and
499,999.
Page is covering narrow media sensor during warm up. Fuser page count between 400,000 and 499,999.
Page may be jammed in fuser exit or redrive area.
Page may be jammed in fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• If page is not visible from front or rear of the printer, a partial piece of a page may be torn off in the fuser covering the narrow media sensor.
• The narrow media sensor or flag may be dislodged or damaged.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Diagnostic information 2-75
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .44
Description Possible causes
202
202
202
202
202
202
.45
.46
.47
.48
.49
.50
Action
Exit sensor may have bounced. Fuser page count between 400,000 and 499,999.
Never sent the divert command to the stacker.
Fuser page count between 400,000 and
499,999.
Exit sensor assembly Go to
“Fuser exit sensor service check” on page 2-138 .
Page is covering the exit sensor during warm up.
Fuser page count between 400,000 and
499,999.
Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Timeout waiting for the page ahead. Fuser page count between 400,000 and 499,999.
Divert media command issued too soon. Fuser page count between
400,000 and 499,999.
Virtual page timed out waiting for last page of job to be safe in the stapler accumulator.
Fuser page count between 400,000 and
499,999.
Paper jam around the fuser exit or redrive area. Fuser page count stopped at 500,000 to preserve data
Page may be jammed in the fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
2-76 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .51
Description Possible causes
202
202
.52
.53
Action
Page did not cleanly exit fuser or redrive area.
Fuser page count stopped at 500,000 to preserve data.
Exit sensor covered too long. Fuser page count stopped at 500,000 to preserve data.
Page is covering narrow media sensor during warm up. Fuser page count stopped at
500,000 to preserve data.
Page may be jammed in fuser exit or redrive area.
Page may be jammed in fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• If page is not visible from front or rear of the printer, a partial piece of a page may be torn off in the fuser covering the narrow media sensor.
• The narrow media sensor or flag may be dislodged or damaged.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Diagnostic information 2-77
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .54
Description Possible causes
202
202
202
202
202
202
.55
.56
.57
.58
.59
.90
Action
Exit sensor may have bounced. Fuser page count stopped at
500,000 to preserve data.
Never sent the divert command to the stacker.
Fuser page count more than 500,000.
Exit sensor assembly.
Go to
“Fuser exit sensor service check” on page 2-138 .
Page is covering the exit sensor during warm up.Fuser page count stopped at 500,000 to preserve data.
Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Timeout waiting for the page ahead. Fuser page count more than
500,000.
Divert media command issued too soon. Fuser page count more than
500,000.
Virtual page timed out waiting for last page of job to be safe in the stapler accumulator.
Fuser page count more than 500,000.
Paper jam around the exit or redrive area.
Fuser page count is not available.
Page may be jammed in fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
2-78 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .91
Description Possible causes
202
202
.92
.93
Action
Page did not cleanly exit fuser or redrive area.
Fuser page count is not available.
Exit sensor covered too long. Fuser page count is not available.
Page is covering narrow media sensor during warm up. Fuser count is not available.
Page may be jammed in the fuser exit or redrive area.
Page may be jammed in the fuser exit or redrive area.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• Make sure the redrive door is complete closed.
• Check the fuser for any signs of wear or contamination. If any are found, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Turn media over to reduce
+W curl.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check any installed output options(s) that may be installed for correct installation and alignment.
• The fuser exit sensor may not be functioning properly.
Go to
“Fuser exit sensor service check” on page 2-138
.
• If page is not visible from front or rear of the printer, a partial piece of a page may be torn off in the fuser covering the narrow media sensor.
• The narrow media sensor or flag may be dislodged or damaged.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Diagnostic information 2-79
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
202 .94
Description Possible causes
202
202
202
202
202
231
.95
.96
.97
.98
.99
.00
Action
Exit sensor may have bounced. Fuser page count is not available.
Never sent the divert command to the stacker.
Fuser page count is not available.
Exit sensor assembly.
Go to
“Fuser exit sensor service check” on page 2-138 .
Page is covering the exit sensor during warm up.
Fuser page count is not available.
Something is keeping the exit sensor in a covered position. A page may not have been cleared from a prior jam.
Check the fuser and area around the fuser assembly for any signs of debris or pieces of paper or media.
Timeout waiting for the page ahead. Fuser page count is not available.
Divert media command issued too soon. Fuser page count is not available.
Virtual page timed out waiting for last page of job to be safe in the stapler accumulator.
Fuser page count is not available.
Paper did not arrive at the duplex input sensor but did leave the printer exit sensor.
• Duplex rear door not fully latched.
• Printer diverter not functioning correctly.
• Duplex feed system not working correctly.
• Printer and duplex not aligned.
• Make sure the duplex assembly rear door is properly latched.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check duplex unit for correct installation and alignment to the printer.
• If available, try another duplex unit. If none is available, go to “231.xx
Jam displays” on page 2-128 .
2-80 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
232 .00
Description Possible causes
233
234
235
.00
.00
.00
Action
Paper did not clear the duplex input sensor but did leave the printer exit sensor.
Paper failed to make duplex doublefeed sensor during turnaround.
Paper did not arrive at duplex exit sensor.
Paper reached the duplex exit sensor but another sheet is still detected over the doublefeed sensor.
• Duplex rear door not fully latched.
• Printer diverter not functioning correctly.
• Duplex feed system not working correctly.
• Printer and duplex not aligned.
• Make sure the duplex assembly rear door is properly latched.
• Check upper redrive diverter and diverter spring for any signs of damage, a loose spring, or binding parts. Repair the redrive as necessary.
• Check duplex unit for correct installation and alignment to the printer.
• If available, try another duplex option. If none is available, go to
.
• Duplex rear door not fully latched.
• Duplex feed system not working correctly.
• Make sure the duplex assembly rear door is properly latched.
• If available, try another duplex option. If none is available, go to
.
• Duplex rear door not fully latched.
• Duplex feed system not working correctly.
• Severely skewed media coming from the printer.
Check the media coming from the printer to the duplex option is not damaged or skewed. If the media is not damaged or skewed, try another duplex option, if available. If not available, replace the duplex option.
Double feed separated in duplex.
• Remove the two sheets from the duplex option and see if the duplex fails again.
Remove the sheets if it fails again.
• Run the duplex Feed 1 and
Feed 2 Tests to see if they
and
“Duplex Feed 2” on page 3-13 . If the tests fail
after several attempts, replace the duplex option. If the tests pass, retry to feed from the printer through the duplex option. If the problem is still present, replace the duplex option.
Diagnostic information 2-81
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
236 00
Description
Paper did not leave the duplex exit sensor.
Possible causes Action
237
237
238
238
.00
.07
.00
.01
Paper did not reach the printer input sensor from the duplex unit.
Duplex paper jam.
There may be other jams in the paper path.
Paper is covering one of the duplex sensors during a reset.
Duplex input sensor covered.
• Duplex jam access tray is not fully latched.
• Printer PTO not driving duplex feed rolls.
• Duplex feed system not working correctly.
• Duplex jam access tray is not fully latched.
• Printer PTO not driving the duplex feed folls.Duplex feed system not working correctly.
• Duplex jam access tray is not fully latched.
• Printer PTO not driving duplex feed rolls.
• Duplex feed system not working correctly.
• Media left in the duplex and
Continue selected.
• Sensor is having mechanical or electrical problems.
• Media left in the duplex and
Continue selected.
• Sensor is having mechanical or electrical problems.
• Make sure the duplex jam access tray is installed correctly
• Make sure the power takeoff shaft and spring are correctly installed and operating properly.
• Try the duplex option again.
If it fails try another duplex option, if available. If another one is not available, replace the duplex option.
• Make sure the duplex jam access tray is installed correctly
• Make sure the power takeoff shaft and spring are correctly installed and operating properly.
• Try the duplex option again.
If it fails try another duplex option, if available. If another one is not available, replace the duplex option.
• Make sure the duplex jam access tray is installed correctly
• Make sure the power takeoff shaft and spring are correctly installed and operating properly.
• Try the duplex option again.
If it fails try another duplex option, if available. If another one is not available, replace the duplex option.
• Remove any sheets from the duplex option.
• Try the duplex option again.
If it fails, try another duplex option, if available. If one is not available, replace the duplex option.
• Remove any sheets from the duplex option.
• Try the duplex option again.
If it fails, try another duplex option, if available. If one is not available, replace the duplex option.
2-82 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
238 .02
Description
Duplex exit sensor covered.
Possible causes Action
238
238
238
238
238
239
239
239
.03
.04
.05
.06
.07
.00
.01
.02
Duplex input and exit sensors covered.
Duplex doublefeed sensor covered.
Duplex doublefeed sensor covered.
Duplex doublefeed and exit sensors covered.
Duplex doublefeed, input, and exit sensors are covered.
Feed error in duplex unit.
Jam declared by a smart device. Immediate stop.
Jam declared by a smart device. Homing allowed stop.
• Media left in the duplex and selected.
Continue
• Sensor is having mechanical or electrical problems.
• Remove any sheets from the duplex option.
• Try the duplex option again.
If it fails, try another duplex option, if available. If one is not available, replace the duplex option.
• Media left in the duplex and selected.
• Media left in the duplex and selected.
Continue
• Sensor is having mechanical or electrical problems.
Continue
• Sensor is having mechanical or electrical problems.
• Remove any sheets from the duplex option.
• Try the duplex option again.
If it fails, try another duplex option, if available. If one is not available, replace the duplex option.
• Remove any sheets from the duplex option.
• Try the duplex option again.
If it fails, try another duplex option, if available. If one is not available, replace the duplex option.
• Media left in the duplex and selected.
Continue
• Sensor is having mechanical or electrical problems.
• Remove any sheets from the duplex option.
• Try the duplex option again.
If it fails, try another duplex option, if available. If one is not available, replace the duplex option.
• Media left in the duplex and selected.
Continue
• Sensor is having mechanical or electrical problems.
• Remove any sheets from the duplex option.
• Try the duplex option again.
If it fails, try another duplex option, if available. If one is not available, replace the duplex option.
• Media left in the duplex and
Continue selected.
• Sensor is having mechanical or electrical problems.
• Remove any sheets from the duplex option.
• Try the duplex option again.
If it fails, try another duplex option, if available. If one is not available, replace the duplex option.
Replace the duplex option.
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
Replace the duplex option.
Replace the duplex option.
Diagnostic information 2-83
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
239 .03
Description Possible causes Action
Replace the duplex option.
239
239
239
239
239
239
241
241
241
241
241
241
.04
.05
.06
.07
.08
.11
.00
.04
.05
.06
.07
.08
Duplex did not send
Device Controls response.
Duplex did not send
Input Device Ready response.
Duplex did not send
Page In Output Device response.
Failed the last page of a staple job.
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
Engine never sent
Select OUtput Device to the duplex unit because the page leaving the duplex never sent Select
Input Device.
Engine never saw Input
Source Read on a page to be picked from the duplex unit that is waiting on a page to pass the input sensor.
Sheet picked from duplex never made it to the input sensor. Slow or delayed feed from the duplex unit.
Paper jam near tray 1
Not applicable to tray 1
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
• Mechanical feed error due to belt slipping.
• Timing error due to feed system.
• Input sensor not working correctly.
Not applicable to tray 1
Failed to pick from tray 1 Paper jam around autocompensator, faulty motor cable, faulty motor, autocompensator gear bind, failed controller card.
DC feed autocompensator stalled on a pick
Paper jam around autocompensator, faulty motor cable, faulty motor, autocompensator gear bind, or failed controller card.
Received lots of dc feed interrupts before losing them.
Paper jam around autocompensator, faulty motor cable, faulty motor, autocompensator gear bind, or failed controller card.
Replace the duplex option.
Replace the duplex option.
Replace duplex option.
Replace the duplex option.
Replace the duplex option.
Check duplex sensor cables for correct installation. If no problem is found with the cables, replace the duplex option.
• Check for jam in tray.
• Check for overloaded tray.
• Check pick assembly and controller card.
• Check for jam in tray.
• Check pick assembly and controller card.
• Check for jam in tray.
• Check pick assembly and controller card.
2-84 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
241 .09
Description Possible causes
Page did not reach input sensor.
If source is tray 1, possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor.
Action
241
241
241
.10
.11
.12
Page was not properly picked from tray 1.
Page was not properly picked from tray 1.
Page was not properly picked from tray 1.
Failure to feed possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past the fill line.
Failure to feed possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past the fill line.
Failure to feed possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past the fill line.
• Fan media.
• Turn media over.
• Reduce amount of media loaded in tray 1.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page A-105
.
• Fan media.
• Turn media over.
• Reduce amount of media loaded in tray 1.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Fan media.
• Turn media over.
• Reduce amount of media loaded in tray 1.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Fan media.
• Turn media over.
• Reduce amount of media loaded in tray 1.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
241
241
241
.13
.14
.15
Not applicable to tray 1
Page was not properly picked from MPT, tray 1, or feeder
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor
Late feed from a tray interfered with the pick retry
Staging of paper in tray 1.
• Fan media.
• Turn media over.
• Reduce amount of media loaded in tray 1.
• Replace the pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Clear any paper jams.
• Fan media.
Diagnostic information 2-85
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
241 .16
Description Possible causes
241
242
242
.17
.00
.02
Failed to feed from tray 1. Pages in the paper path have been flushed to the output bin.
Not applicable to tray 1.
• Paper jam
• Worn pick tires.
Paper jam near tray 2.
• Paper jam.
• Failed pass thru sensor.
Jam declared by a smart device. Immediate stop.
Fault reported by options tray 2:
• Paper jam
• Motor or motor cable failure
• Sensor failure
Action
242
242
242
242
.03
.04
.05
.06
Jam declared by a smart device. Homing allowed stop.
Fault reported by options tray 2:
• Paper jam
• Motor failure
• Sensor failure
Option tray pass thru sensor never became covered.
Option tray pass thru sensor never became uncovered.
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor
If source is tray 3, possible cause include:
• Paper path bind when feeding from tray 2 though tray 1
• Damaged PTO shaft
Paper jam or failed sensor.
• Clear paper jam.
• Check sensor.
• Clear all jams.
• Check motor cables.
• Check and/or replace tray motor.
• Check and/or replace sensor(s).
• Replace entire option.
• Clear all jams.
• Check motor cables.
• Check/replace tray motor.
• Check and/or replace sensor(s).
• Replace entire option.
• Clear all jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check and/or replace input sensor.
• Clear all jams.
• Check/replace pass thru sensor.
• Check for jam in tray.
• Check pick assembly and controller card.
242 .10
Failed to pick from tray 2 • Paper jam around autocompensator
• Faulty motor cable
• Faulty motor
• Autocompensator gear bind
• Failed controller card.
Failed to feed from tray
2
Failed to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
2-86 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
242 .13
Description
Paper over tray 2 pass thru sensor on warm-up.
Possible causes
• Paper left in path
• Failed pass thru sensor
Action
242 .16
• Clear media jams.
• Check/replace pass thru sensor.
• Clear media jams.
• Replace pick tires.
• Check/replace input sensor.
242
243
243
.17
.00
.02
Failed to feed from tray 2. Pages in the paper path have been flushed to the output bin.
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past the fill line
• Failed pass thru sensor
One or more trays located above the source tray as been removed.
• Tray removed
• Sensors faulty
Paper jam near tray 3
Jam declared by smart device. Immediate stop.
• Paper jam
• Failed pass thru sensor
Fault reported by options tray 3:
• Paper jam
• Motor or motor cable failure
• Sensor failure
• Reinstall tray.
• Check sensors.
243
243
243
243
.03
.04
.05
.6
Jam declared by smart device. Homing allowed to stop
Fault reported by options tray 3:
• Paper jam
• Motor failure
• Sensor failure
Option tray pass thru sensor never became covered.
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor
Option tray pass thru sensor never became uncovered.
• Paper jam
• Failed sensor
Failed to pick from tray 3 • Paper jam around autocompensator
• Faulty motor cable
• Faulty motor
• Autocompensator gear bind
• Failed controller card
• Clear media jam.
• Check sensor.
• Clear all media jams.
• Check motor cables.
• Check/replace tray motor.
• Check/replace sensor(s).
• Replace entire option.
• Clear all media jams.
• Check/replace tray motor.
• Check/replace sensor(s).
• Replace entire option.
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
• Check PTO shaft.
• Check all media jams.
• Check/replace pass thru sensor.
• Check for jam in tray.
• Check pick assembly and controller card.
Diagnostic information 2-87
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
243 .10
Description
Fail to feed from tray 3
Possible causes
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor
Action
243 .13
Paper over tray 3 pass thru sensor on warm-up.
• Paper left in path
• Failed pass thru sensor
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
• Clear media jams.
• Check/replace pass thru sensor.
243
243
243
.15
.16
.17
Late feed from a tray interfered with the pick retry.
Failed to feed from tray
3. Pages in the paper path have been flushed to the output bin.
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed pass thru sensor
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
• Reinstall tray.
• Check sensors.
244
244
244
244
.00
.02
.03
.04
One or more trays located above the source tray have been removed.
Paper jam near tray 4.
• Tray removed
• Sensors faulty
• Tray removed
• Sensors faulty
Jam declared by a smart device. Immediate stop.
Fault reported by options tray 4:
• Paper jam
• Motor or motor cable failure
• Sensor failure
Jam declared by a smart device. Homing allowed to stop.
Fault reported by options tray 4:
• Paper jam
• Motor failure
• Sensor failure
Option tray pass thru sensor never became covered.
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor
If source is tray 5, possible causes include:
• Paper path bind when feeding from tray 2 through tray 1
• Damaged PTO shaft.
• Clear media jams.
• Check sensor.
• Clear all media jams.
• Check motor cables.
• Check/replace tray motor.
• Check/replace sensor(s).
• Replace entire option.
• Clear all media jams.
• Check motor cables.
• Check/replace tray motor.
• Check/replace sensor(s).
• Replace entire option.
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
• Check PTO shaft.
2-88 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
244 .05
244 .06
Description
Option tray pass thru sensor never became uncovered.
Possible causes
Paper jam
Failed sensor
Action
• Clear all jams.
• Check/replace pass thru sensor.
• Check for jam in tray.
• Check pick assembly and controller card.
244
244
244
.10
.13
.15
Failed to pick from tray 4 • Paper jam around autocompensator
• Faulty motor cable
• Faulty motor
• Autocompensator gear bind
• Failed controller card
Failure to feed from tray 4.
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor
Paper over tray 4 pass thru sensor on warm-up.
• Paper left in path.
• Failed pass thru sensor
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
• Clear media jams.
• Check/replace pass thru sensor.
•
244
244
245
245
245
.16
.17
.00
.02
.03
Late feed from a tray interfered with the pick retry.
•
Failed to feed from tray 4. Pages in the paper path have been flushed to the output bin.
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Could also be a failed pass thru sensor
One or more trays location above the source tray have been removed.
• Tray removed
• Sensors faulty
Paper jam near tray 5.
• Paper jam
• Failed pass thru sensor
Jam declared by a smart device. Immediate stop.
Fault reported by options tray 5:
• Paper jam
• Motor or motor cable failure
• Sensor failure
Jam declared by a smart device. Homing allowed to stop.
Fault reported by options tray 5:
• Paper jam
• Motor failure
• Sensor failure
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
• Reinstall the tray.
• Check sensors.
• Clear media jam.
• Check sensor.
• Clear all media jams.
• Check motor cables.
• Check/replace tray motor.
• Check/replace sensor(s).
• Replace entire option.
• Clear all media jams.
• Check motor cables.
• Check/replace tray motor.
• Check/replace sensor(s).
• Replace entire option.
Diagnostic information 2-89
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
245 .04
Description
Option tray pass thru sensor never became covered.
Possible causes
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor
Action
245
245
.05
.06
Option tray pass thru sensor never became uncovered.
Paper jam
Failed sensor
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
• Clear all jams.
• Check/replace pass thru sensor.
• Check for jam in tray.
• Check pick assembly and controller card.
245
245
.10
.13
Failed to pick from tray 5 • Paper jam around autocompensator
• Faulty motor cable
• Faulty motor
• Autocompensator gear bind
• Failed controller card
Failure to feed from tray 5.
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Failed sensor
Paper over tray 5 pass thru sensor on warm-up.
• Paper left in path.
• Failed pass thru sensor
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
• Clear media jams.
• Check/replace pass thru sensor.
245 .15
245.1
6
.16
245
250
250
250
.17
.00
.01
.02
Late feed from a tray interfered with the pick retry.
Failed to feed from tray 5. Pages in the paper path have been flushed to the output bin.
Failure to feed. Possible causes include:
• Edge locking
• Worn or contaminated pick tires
• Overfilling of tray past fill line
• Could also be a failed pass thru sensor
• Tray removed
• Sensors faulty
One or more trays location above the source tray have been removed.
Paper jam near the multipurpose feeder.
Option tray pass thru sensor never became covered.
Option tray pass thru sensor never became uncovered.
• Clear media jams.
• Replace pick tires. See
“Integrated tray autocompensator pick roll assembly removal” on page 4-105
.
• Check/replace input sensor.
• Reinstall the tray.
• Check sensors.
2-90 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
250 .06
Description Possible causes
Page did not reach input sensor.
Paper jam around the multipurpose tray.
Action
250
250
250
250
250
.07
.08
.09
.10
.11
Page was not properly picked from multipurpose feeder.
Page was not properly picked from multipurpose feeder.
Page was not properly picked from multipurpose feeder.
Paper jam around the multipurpose feeder.
Paper jam around the multipurpose feeder.
Paper jam around the multipurpose feeder.
• Check for jam in tray.
• Check pick assembly and controller card.
• Check for jam in tray.
• Check pick assembly and controller card.
• Check for jam in tray.
• Check pick assembly and controller card.
• Check for jam in tray.
• Check the pick assembly and controller card.
• Check for jam in tray.
• Check pick assembly and controller card.
• Check for jam in tray.
• Check the pick assembly and controller card.
260
260
260
260
260
260
.00
.01
.02
.05
.06
.07
Page was not properly picked from multipurpose feeder.
Paper jam around the multipurpose feeder.
Failed to feed from multipurpose feeder.
Pages in the paper path have been flushed to the output bin.
Paper jam around the multipurpose feeder.
Paper jam near the envelope feeder.
Jam declared by a smart device. Immediate stop.
Jam declared by a smart device. Homing allowed stop.
Envelope feeder pass thru sensor never became uncovered.
Envelope feeder pass thru sensor never became covered.
Failed to pick from the envelope feeder.
Paper jam around the envelope feeder.
260
260
260
.10
.11
.12
Page did not reach input sensor from envelope feeder.
Paper jam around envelope feeder
Page did not reach input sensor from envelope feeder.
Paper jam around envelope feeder
Page did not reach input sensor from envelope feeder.
Paper jam around envelope feeder
• Remove feeder and clear jam.
• Replace feeder.
• Remove feeder and clear jam.
• Replace feeder.
• Remove feeder and clear jam.
• Replace feeder.
• Remove feeder and clear jam.
• Replace feeder.
Diagnostic information 2-91
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
260 .13
Description Possible causes
260
260
260
290
290
290
290
291
291
291
292
.14
.15
.16
.00
.01
.02
.10
.00
.01
.02
.00
Action
Paper in envelope feeder on warm-up.
Page was not properly picked from envelope feeder.
Page was not properly picked from envelope feeder.
Paper jam around envelope feeder.
Paper jam around envelope feeder.
Failed to feed from envelope feeder. Pages in the paper path have been flushed to the output bin.
Static jam—ADF Interval
Sensor
Paper jam around envelope feeder.
• The paper may be stuck in the ADF at or over the interval sensor.
• Interval sensor may be malfunction.
ADF Pickup Jam.
ADF Feed Jam.
Static jam—First Scan
Sensor.
• Remove feeder and clear jam.
• Replace feeder.
Go to
“290.00 Error code service check” on page 2-96
.
The ADF attempted to stage a page but the leading edge of the page did not reach the interval sensor.
The leading edge of the page reached the interval sensor but did not reach the first scan sensor.
Paper may be stuck in the ADF at the first scan sensor or the first scan sensor may be malfunctioning.
Go to
“290.01 Error code service check” on page 2-98
.
Check for proper operation of the first scan sensor. If the sensor is opening properly and no other problem is found, go to
“290.02 Error code service check” on page 2-100
.
Check for any media or obstruction over the first scan sensor. If no problem is found, go to
“290.10 Error code service check” on page 2-102 .
Static Jam—Second
Scan Sensor.
• Remove feeder and clear jam.
• Replace feeder.
• Remove feeder and clear jam.
• Replace feeder.
First ADF Scan Sensor
Jam.
Second ADF Scan
Sensor
ADF Cover Open Jam
Paper may be stuck in the ADF at the second scan sensor or the second scan sensor is not operating properly.
Check for any media or obstruction over the second scan sensor. If no problem is found, go to
“291.00 Error code service check” on page 2-104 .
The second sensor detected the leading edge of the paper but never detected the training edge. The first scan sensor detected the trailing edge of the paper.
Go to
“291.01 Error code service check” on page 2-105 .
The first scan sensor has detected the trailing edge of the page, but the second scan sensor did not detect the leading edge of the page.
Clear any media from the ADF and close the cover. If this does not fix the problem, then go to
“291.02 Error code service check” on page 2-106
.
The ADF cover was opened while the
ADF was scanning.
Clear any paper from the ADF and close the cover. If this does not fix the problem, then go to
“292.00 Error code service check” on page 2-107
.
2-92 Service Manual
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
293 .00
Description Possible causes
294
294
294
295
287
297
298
.00
.01
.02
.03
.13
.14
.01
Action
Paper Missing Jam
Static Jam—ADF Exit
Sensor
An attempt was made to force an ADF scan, by a custom job, page level jam recovery, or so on, with no paper in the
ADF input tray or the paper was removed from the ADF input tray just as it was being staged. The paper present sensor may be malfunctioning.
Make sure the media is loaded in the ADF when starting an
ADF scan. If no problem is found, go to
“293 Error code service check” on page 2-108 .
The page is stuck in the ADF at the exit sensor or the exit sensor is malfunctioning.
Check for any jammed pages in the ADF and remove. If the problem persists, go to
Error code service check” on page 2-109 .
ADF Eject Jam
ADF Exit Jam Sensor
Off
ADF Exit Jam Sensor
On
The exit sensor may not be operating properly or malfunctioning.
The exit sensor may not be operating properly or malfunctioning.
The exit sensor may not be operating properly or malfunctioning.
Verify that the exit sensor is operating properly. If the problem persists and the exit sensor seems to be operating properly, go to
“294.01 Error code service check” on page 2-110 .
Verify the exit sensor is operating properly. If the problem persists and the exit sensor seems to be operating properly, go to
“294.02 Error code service check” on page 2-112 .
Verify that the exit sensor is operating properly. If the problem persists and the exit sensor seems to be operating properly, go to
“294.03 Error code service check” on page 2-113 .
Clean Scanner Backing
Strip
Clean Scanner Glass
Scanner Missing—Front
Side Cable Unplugged
The flatbed white cushion inside the ADF is dirty.
Clean the flatbed white cushion.
See
“Cleaning the scanner glass, cushions, and strips” on page 6-2 .
The scanner document glass is dirty.
One of the cables on the rear of the scanner is unplugged or loose.
Clean the scanner glass for both the flatbed and ADF. See
“Cleaning the scanner glass, cushions, and strips” on page 6-2 .
Check the cables on the rear of the scanner to make sure they are plugged in and fastened securely. If no problem is found
with the cables, go to “298.01
Error code service check— models X644e/X646e” on page 2-115 .
Diagnostic information 2-93
7002-xxx
User attendance messages—paper jams and paper handling errors (2xx.xx)
Code
Sub code
298 .02
Description Possible causes
Scanner Missing—Rear
Side Cable Unplugged
One of the cables on the rear of the scanner is unplugged or loose.
Action
Check the cables on the rear of the scanner to make sure they are plugged in and fastened securely. If no problem is found
with the cables, go to “298.02
Error code service check” on page 2-115 .
2-94 Service Manual
7002-xxx
Service checks
Anytime the system board is replaced, the Configuration ID must be reset in NVRAM. Go to
“Configuration ID” on page 3-19
.
Review the following information before performing any service checks.
• Paper feed problems (especially paper jams): Go to
“Display Log” on page 3-21 and check the printer
event log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option.
• Paper feed problems with error message: Use the
“Sub error codes for 8xx, 9xx, and 2xx error codes” on page 2-13 to help diagnose the problem.
•
Print quality problems: Go to
“Printing Quality Pages” on page 3-7 and print a test page to help
diagnose problems before changing any settings or working on the printer.
• Use the resident diagnostics test provided to help isolate a problem before taking the machine apart or removing any options.
202.03 Error code service check
The spring on the narrow media sensor flag may not be working correctly. When the sensor flag is made, it does not return to the correct position.
1
2
FRU
Fuser narrow media sensor flag and spring
Fuser assembly
Action
Remove the fuser narrow media sensor. See
“Fuser narrow media sensor removal” on page 4-88 . Inspect the flag and spring. If there
is damage or the flag and spring do not operator correctly, replace the fuser narrow media sensor flag and spring. See
“Fuser narrow media flag and spring removal” on page 4-90
.
If this does not correct the problem, go to step 2.
Replace the fuser assembly. See “Fuser assembly removal” on page 4-79
.
202.06 Error code service check
The spring on the fuser exit sensor flag may not be working correctly. When the sensor flag is made, it does not return to the correct position.
1
FRU
Fuser exit sensor flag and spring
2 Fuser assembly
Action
Remove the fuser exit sensor . See ). Inspect the flag and spring. If there is damage or the flag and spring do not operator correctly, replace the fuser exit sensor flag and spring. See
“Fuser exit sensor flag and spring removal” on page 4-83 .
If this does not correct the problem, go to step 2.
Replace the fuser assembly. See “Fuser assembly removal” on page 4-79
.
Diagnostic information 2-95
7002-xxx
290.00 Error code service check
Static jam—ADF interval sensor (A).
A
Note: Before starting this service check, make sure the interval sensor cable is correctly installed.
1
2
FRU
ADF
3 Interval sensor cable
(interval sensor to CN10 on the MDC card)
4
Interval sensor
Motor driver card
Action
Check for any signs of paper or other debris that might be present in the ADF assembly over the interval sensor.
If nothing found, go to step 2.
Enter the Diagnostic Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS and then select Sensor Tests . Check the interval sensor for correct operation.
Note: You can check the interval sensor by putting a sheet of paper over the sensor. This is easier to perform by first removing the pick arm assembly.
If the sensor fails the test, go to step 3.
Check to make sure the interval sensor cable is correctly installed at the sensor and atCN10 on the motor driver card. If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4.
Turn the power off and disconnect CN10 on the motor driver card.
Measure the voltages at the board:
Interval sensor—reflective type
(normally closed)
Connector CN10 (motor driver card)
CN10—Pin 7 0 V dc
CN10—Pin 8
CN10—Pin 9
+5.0 V dc
+5.0 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card. If correct go to step 5.
2-96 Service Manual
7002-xxx
FRU
5 Interval sensor—electrical checks
Action
Turn the power off and reconnect CN10 to the motor driver card.
Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (paper over the sensor).
Interval sensor—reflective type (normally closed)
Connector CN10 (motor driver card)
Pin number
CN10—Pin 7
Sensor closed (uncovered
0 V dc
Sensor open (covered)
0 V dc
CN10—Pin 8
CN10—Pin 9
+0.03 V dc
+5.0 V dc
Note: All voltages are approximate values.
+5.0 V dc
+5.0 V dc
If the voltages are incorrect replace the interval sensor. If this does not fix the problem, replace the complete ADF assembly.
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
Diagnostic information 2-97
7002-xxx
290.01 Error code service check
ADF pickup jam.
Note: Before starting this service check, make sure the interval sensor (A) cable is correctly installed.
1
FRU
Pickup arm assembly
A
2 Pickup arm solenoid springs
3 Pickup arm solenoid springs
4 Pickup arm solenoid
5 Motor driver card
Action
Check to make sure the pickup arm is correctly installed. If not installed correctly, reinstall properly.
If installed correctly, check the pickup arm assembly for any signs of damage or broken parts. If a problem is found, replace the pickup arm assembly.
Check the pickup arm solenoid springs to make sure they are correctly attached to the jam removal knob pulley. If not installed correctly, reinstall.
If installed correctly, go to step 3.
Check for any signs of broken or damaged pickup arm solenoid assembly springs. If either spring is broken or damaged, replace the
solenoid assembly which contains both springs. See “ADF pick assembly removal” on page 4-7
.
If no problem is found, go to step 4.
Turn the power off, disconnect CN5 on the motor driver card.
Measure the resistance between C5-1 and CN5-2. The resistance should measure approximately 41.0 ohms. If correct, go to step 5.
If incorrect, disconnect the solenoid from the solenoid cable on the front side of the ADF near the solenoid, and measure the resistance between pins 1 and 2 on the cable attached to the solenoid. The resistance should measure approximately 41.0 ohms. If incorrect, replace the solenoid assembly. If correct, replace the ADF assembly.
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
Reconnect CN5 to the motor driver card, and measure the voltage at
CN5-1 and CN5-2. The voltage should measure approximately
+25.0 V dc. If incorrect, replace the motor driver card.
If correct, go to step 6.
2-98 Service Manual
7002-xxx
FRU
6 ADF feed motor
7 Scan motor belt
8 Interval sensor—electrical checks
Action
Check the ADF feed motor for proper operation.
Turn the power off, disconnect CN2 on the motor driver card, and measure the voltages on CN2.
ADF feed motor
Connector CN2 (motor driver card)
Pin number Static
CN2—Pin 1
CN2—Pin 2
CN2—Pin 3
CN2—Pin 4
+1.5 V dc
+1.5 V dc
+1.5 V dc
+1.5 V dc
CN2—Pin 5
CN2—Pin 6
+1.5 V dc
+1.5 V dc
Note: All voltages are approximate values.
Operating
+24 V dc
+24 V dc
+24 V dc
+24 V dc
+24 V dc
+24 V dc
If the voltages are incorrect, replace the motor driver card. If incorrect, turn the power off, reconnect the motor cable to CN2, and measure the voltages on the scan motor connector. If incorrect, replace the scan motor.
If correct, go to step 7.
Check the scan motor drive belt for any signs of wear or damage or the belt off the gear. If the belt is off the gear, reinstall. If the belt is worn or damaged, replace the belt. If no problem is found replace the
complete ADF assembly. See “ADF complete assembly removal” on page 4-15
.
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
Turn the power off and reconnect CN10 to the motor driver card.
Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (paper over the sensor).
Interval sensor—reflective type (normally closed)
Connector CN10 (motor driver card)
Pin number Sensor closed (uncovered Sensor open (covered)
CN10—Pin 7
CN10—Pin 8
CN10—Pin 9
0 V dc
+0.03 V dc
+5.0 V dc
Note: All voltages are approximate values.
0 V dc
+5.0 V dc
+5.0 V dc
If the voltages are incorrect replace the interval sensor. If this does not fix the problem, replace the complete ADF assembly.
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
Diagnostic information 2-99
7002-xxx
290.02 Error code service check
ADF feed jam.
A
Note: Before starting this service check, make sure the first scan sensor (A) cable is correctly installed.
1
FRU
ADF
2 First scan sensor
3 First scan sensor cable
(first scan sensor to CN10 on the MDC card)
4 Motor driver card
Action
Check for any signs of paper or other debris that might be present in the ADF assembly over the interval sensor but short of the first scan sensor. Remove any media found in the ADF, and retry by running the scanner feed tests. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Feed
Tests . If the paper fails to reach the first scan sensor, go to step 2.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests. Check the first scan sensor for correct operation.
Note: Check the first scan sensor by manually feeding a sheet of paper through the ADF and checking the sensor for correct operation.
If the sensor fails the test, go to step 3.
Check to make sure the interval sensor cable is correctly installed at the sensor CN10 on the motor drive card. If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4.
Turn the power off, and disconnect CN10 on the motor driver card.
Measure the voltages in the table below:
First scan sensor—reflective type
(normally closed)
Connector CN10 (motor driver card)
CN10—Pin 10
CN10—Pin 11
0 V dc
+5 V dc
CN10—Pin 12 +5 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card. If correct, go to step 5.
2-100 Service Manual
FRU
5 First scan sensor— electrical checks
6
7
ADF scan motor
Scan motor belt
7002-xxx
Action
Turn the power off and reconnect CN10 to the motor driver card.
Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (paper over the sensor).
First scan sensor
Connector CN10 (motor driver card)
Pin number
CN10—Pin 10
Sensor closed (uncovered) Sensor open (covered)
0 V dc 0 V dc
CN10—Pin 11
CN10—Pin 12
+5.0 V dc
+0.03 V dc
Note: All voltages are approximate values.
+5.0 V dc
+5.0 V dc
If the voltages are incorrect, replace the first scan sensor. If the voltages are correct, go to step 6.
Check the ADF scan motor for proper operation. Turn the power off, disconnect CN3 on the motor driver card, and measure the voltages on CN3 on the card.
ADF scan motor
Connector CN3 (motor driver card)
Pin number Static
CN3—Pin 1
CN3—Pin 2
CN3—Pin 3
+1.5 V dc
+1.5 V dc
+1.5 V dc
CN3—Pin 4
CN3—Pin 5
CN3—Pin 6
+1.5 V dc
+1.5 V dc
+1.5 V dc
Note: All voltages are approximate values.
Operating
+24 V dc
+24 V dc
+24 V dc
+24 V dc
+24 V dc
+24 V dc
If the voltages are incorrect, replace the motor driver card. If correct, turn the power off, reconnect the motor cable to CN3, and measure the voltages on the scan motor connector (see the table above). If correct, go to step 7.
Check the scan motor drive belt for any signs of wear or damage or the belt is off the gear. If the belt is off the gear, reinstall. If the belt is worn or damaged, replace the belt. If no problem is found, Replace
the complete ADF assembly. See “ADF complete assembly removal” on page 4-15
.
Note: Whenever the complete ADF assembly is replaced, is necessary to perform the scanner registration. See
“Scanner registration” on page 4-4 .
Diagnostic information 2-101
7002-xxx
290.10 Error code service check
Static jam—first scan sensor (A)
A
Note: Before starting this service check, make sure the first scan sensor cable is correctly installed.
1
FRU
ADF
2 First scan sensor
3 First scan sensor cable
(first scan sensor to CN10 on the MDC card)
4 Motor driver card
Action
Check for any signs of paper or other debris that might be present in the ADF assembly over the first scan sensor. Remove any media found over the sensor, and retry by running the scanner feed tests.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Feed Tests . If the media jams over the first scan sensor, go to step 2.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check the first scan sensor for correct operation.
Note: Check the first scan sensor by manually feeding a sheet of paper through the ADF and checking the sensor for correct operation.
If the sensor fails the test, go to step 3.
Check to make sure the first scan cable is correctly installed at the sensor CN10 on the motor drive card. If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4.
Turn the power off, and disconnect CN10 on the motor driver card.
Measure the voltages in the table below:
First scan sensor—reflective type
(normally closed)
Connector CN10 (motor driver card)
CN10—Pin 10
CN10—Pin 11
0 V dc
+5 V dc
CN10—Pin 12 +5 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card. If correct, go to step 5.
2-102 Service Manual
FRU
5 First scan sensor— electrical checks
7002-xxx
Action
Turn the power off, and reconnect CN10 to the motor driver card.
Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (paper over the sensor).
First scan sensor
Connector CN10 (motor driver card)
Pin number
CN10—Pin 7
Sensor closed (uncovered)
+0 V dc
Sensor open (covered)
0 V dc
CN10—Pin 8
CN10—Pin 9
+0.03 V dc
+5.0 V dc
Note: All voltages are approximate values.
+5.0 V dc
+5.0 V dc
If the voltages are incorrect, replace the first scan sensor. If this does not fix the problem, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
Diagnostic information 2-103
7002-xxx
291.00 Error code service check
Static jam—second scan sensor (A).
A
Note: Before starting this service check, make sure the second scan sensor cable is correctly installed.
1
FRU
ADF
2
3 Second scan sensor cable
(second scan sensor to
CN9 on the MDC card)
4
Second scan sensor
Motor driver card
Action
The media is jammed or stuck in the ADF at the second scan sensor.
Check for any signs of paper or other debris that might be present or jammed in the ADF assembly around the second scan sensor.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check the second scan sensor for correct operation.
Note: To manually activate the sensor, you can either open the jam removal tray (it is necessary to defeat the jam tray sensor by placing a piece of paper in the sensor to turn off the jam tray message on the display), or you can manually feed a piece of paper through the ADF.
If the sensor fails the test, go to step 3.
Check to make sure the first scan cable is correctly installed at the sensor CN9 on the SCC (scanner control card in the ADF). If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4.
Turn the power off, and disconnect CN9 on the motor driver card.
Measure the voltages in the table below:
First scan sensor—reflective type
(normally closed)
Connector CN9 (motor driver card)
CN9—Pin 4 0 V dc
CN9—Pin 5
CN9—Pin 6
+5 V dc
+5 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card. If correct, go to step 5.
2-104 Service Manual
FRU
5 Second scan sensor— electrical checks
7002-xxx
Action
Turn the power off, and reconnect CN9 to the motor driver card.
Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (sensor flag activated).
Second scan sensor
Connector CN9 (motor driver card)
Pin number
CN9—Pin 4
Sensor closed
+0 V dc
CN9—Pin 5
CN9—Pin 6
+1.16 V dc
+5.0 V dc
Note: All voltages are approximate values.
Sensor open
0 V dc
+1.16 V dc
+0.15 V dc
If the voltages are incorrect, replace the second scan sensor. If this does not fix the problem, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
291.01 Error code service check
First ADF scan sensor (A) jam.
A
Note: Before starting this service check, make sure the first scan sensor cable is correctly installed.
1
FRU
ADF
2 Area around the first scan sensor
Action
The leading edge of the media was detected by the first scan sensor, but never detected by the trailing edge.
Clear any media that may be in the ADF. Enter Diagnostics Menu
(turn on MFP while holding 3 and 6 ), select SCANNER TESTS, load some sheets of paper in the ADF paper tray, and select Feed Tests .
If the error continues at or near the same point, go to step 2.
Check the area around the first scan sensor for anything that might cause the stop or jam prior to exiting the first scan sensor. If the problem continues and you cannot find anything causing this jam, replace the complete ADF assembly.
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
Diagnostic information 2-105
7002-xxx
291.02 Error code service check
Second ADF scan sensor (A) jam.
A
Note: Before starting this service check, make sure the sensor cable is correctly installed.
1
FRU
ADF
2 ADF feed gears and hardware
3 Second scan sensor cable
(second scan sensor to
CN9 on the MDC card)
Action
The second scan sensor has detected the leading edge of the sheet but did not detect the training edge. The first scan sensor detected the leading edge. Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Feed Tests .
Load several sheets through the ADF to check for any jams prior to the second scan sensor. If the jam is persistent, go to Step 2.
Check the ADF feed gears, pulleys, and hardware for any signs of binding, broken, or damaged parts. If any problems are found, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
Note: To help isolate a problem with the ADF feed system you can run the Feed Test from the SCANNER TESTS in the Diagnostics
Menu. Put several sheets of media in the ADF tray, and observe the gears, motor, belts, and other hardware for any signs of a malfunction that might cause the media not to reach the second scan sensor.
Check to make sure the second scan sensor cable is correctly installed at the sensor at CN9 on the MDC (motor driver card in the
ADF). If the cable is not installed correctly, reinstall the cable. If installed correctly, go to step 4.
2-106 Service Manual
7002-xxx
FRU
4 Motor driver card
5 Second scan sensor— electrical checks
Action
Turn the power off, and disconnect CN9 on the motor driver card.
Measure the voltages in the table below:
Second scan sensor—reflective type
(normally closed)
Connector CN9 (motor driver card)
CN9—Pin 4
CN9—Pin 5
0 V dc
+5 V dc
CN9—Pin 6 +5 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card. If correct, go to step 5.
Turn the power off and reconnect CN9 to the motor driver card.
Measure the voltages in the table below with the sensor in normal operations (sensor closed) and with the sensor open (sensor flag activated).
Second scan sensor—interrupter type (normally closed)
Connector CN9 (motor driver card)
Pin number Sensor closed Sensor open
CN9—Pin 4
CN9—Pin 5
CN9—Pin 6
0 V dc
+1.16 V dc
+5.0 V dc
Note: All voltages are approximate values.
0 V dc
+1.16 V dc
+0.15 V dc
If the voltages are incorrect, replace the second scan sensor. If this does not fix the problem, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
292.00 Error code service check
ADF cover open jam.
1
FRU
ADF upper top cover
Action
Check the ADF upper top cover to make sure it closes properly and does not come loose or pop up while the ADF is scanning.
Diagnostic information 2-107
7002-xxx
293 Error code service check
Paper missing jam.
Note: Before starting this service check, make sure the sensor cable is correctly installed.
1
FRU
ADF
2 Paper present sensor
3 Paper present cable
Motor driver card
Action
Check the ADF for any media that might be jammed in the ADF. Turn the MFP off and then back on. Feed several sheets of media through the ADF. If the error still occurs, go to step 2.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check the paper present sensor for correct operation by inserting a sheet of paper into the ADF paper tray to activate the paper present sensor. If the sensor does not operate properly, go to step 3.
Measure the voltages shown in the table below:
Paper present sensor—interrupter type (normally closed)
Connector CN10 (motor driver card)
Pin number
CN10—Pin 4
Sensor closed
0 V dc
Sensor open
0 V dc
CN10—Pin 5
CN10—Pin 6
+4.3 V dc
+1.6 V dc
Note: All voltages are approximate values.
+0.25 V dc
+1.6 V dc
If the voltages are incorrect, turn the power off, disconnect the cable attached to CN10 on the motor driver card, and measure the voltages in the table below:
Paper present sensor—interrupter type
(normally closed)
Connector CN10 (motor driver card)
CN10—Pin 4
CN10—Pin 5
CN10—Pin 6
0 V dc
+4.3 V dc
+5 V dc
Note: All voltages are approximate values.
If the voltages are incorrect, replace the motor driver card. If the
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
2-108 Service Manual
294.00 Error code service check
Static jam—ADF exit sensor (A).
7002-xxx
A
Before starting this service check, Check the ADF exit sensor cable for correct installation.
1
FRU
ADF—jammed media
2 ADF exit sensor flag
3 ADF exit sensor
4 Motor driver card
Action
Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag. Remove any media or debris. If nothing is found, go to step 2.
Check the exit sensor flag to make sure it operates freely and does not hang or bind. If the flag does not operate correctly and cannot be made to operate correctly, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
If the flag operates correctly, go to step 3.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check the ADF exit sensor for correct operation.
Note: You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF.
If the sensor fails the test, go to step 4.
Turn the power off, and disconnect CN9 on the motor driver card.
Measure the voltages in the table below:
Interval sensor—interrupter type
(normally closed)
Connector CN9 (motor driver card)
CN9—Pin 1 0 V dc
CN9—Pin 2
CN9—Pin 3
+5 V dc
+5 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card. If correct, go to step 5.
Diagnostic information 2-109
7002-xxx
FRU
5 ADF exit sensor—electrical checks
Action
Turn the power off, and reconnect CN9 to the motor driver card.
Measure the voltages in the table below with the sensor in normal operation (sensor closed) and the sensor open (sensor flag activated).
ADF exit sensor—interrupter type (normally closed)
Connector CN9 (motor driver card)
Pin number
CN9—Pin 1
Sensor closed
0 V dc
Sensor open
0 V dc
CN9—Pin 2
CN9—Pin 3
+1.16 V dc
+5.0 V dc
Note: All voltages are approximate values.
+1.16 V dc
+0.15 V dc
If the voltages are incorrect, replace the ADF exit sensor. If this does not fix the problem, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
294.01 Error code service check
ADF eject jam.
Note: Before starting this service check, make sure the ADF exit sensor (A) cable is installed correctly.
1
FRU
ADF—jammed media
A
Action
Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag. Remove any media or debris. If nothing is found, go to step 2.
2-110 Service Manual
FRU
2 ADF exit sensor flag
3
4
ADF exit sensor
Motor driver card
7002-xxx
Action
Check the exit sensor flag to make sure it operates freely and does not hang or bind. If the flag does not operate correctly and cannot be made to operate correctly, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
If the flag operates correctly, go to step 3.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check the ADF exit sensor for correct operation.
Note: You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF.
If the sensor fails the test, go to step 4.
Turn the power off, and disconnect CN9 on the motor driver card.
Measure the voltages in the table below:
Exit sensor—interrupter type
(normally closed)
Connector CN9 (motor driver card)
CN9—Pin 1
CN9—Pin 2
0 V dc
+5 V dc
CN9—Pin 3 +5 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card.
If the error persists, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
Diagnostic information 2-111
7002-xxx
294.02 Error code service check
ADF exit jam sensor (A) off.
A
Note: Before starting this service check, make sure the sensor cable is installed correctly.
1
FRU
ADF—jammed media
2 ADF exit sensor flag
3 ADF exit sensor
4 Motor driver card
Action
Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag. Remove any media or debris. If nothing is found, go to step 2.
Check the exit sensor flag to make sure it operates freely and does not hang or bind. If the flag does not operate correctly and cannot be made to operate correctly, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
If the flag operates correctly, go to step 3.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check the ADF exit sensor for correct operation.
Note: You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF.
If the sensor fails the test, go to step 4.
Turn the power off and disconnect CN9 on the motor driver card.
Measure the voltages in the table below:
Interval sensor—interrupter type
(normally closed)
Connector CN9 (motor driver card)
CN9—Pin 1 0 V dc
CN9—Pin 2
CN9—Pin 3
+5 V dc
+5 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card.
If the voltage is correct, go to step 5.
2-112 Service Manual
7002-xxx
FRU
5 ADF exit sensor—electrical checks
Action
Turn the power off, and reconnect CN9 to the motor driver card.
Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (sensor flag activated).
ADF exit sensor—interrupter type (normally closed)
Connector CN9 (motor driver card)
Pin number
CN9—Pin 1
Sensor closed
0 V dc
Sensor open
0 V dc
CN9—Pin 2
CN9—Pin 3
+1.16 V dc
+5.0 V dc
Note: All voltages are approximate values.
+1.16 V dc
+0.15 V dc
If the voltages are incorrect, replace the ADF exit sensor. If this does not fix the problem, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
294.03 Error code service check
ADF exit jam sensor on. This error generally indicates that the ADF exit sensor (A) is defective, exit sensor cable is open, or the voltages on the motor driver card at pins 1, 2, or 3 are incorrect.
A
Note: Before starting this service check, make sure the sensor cable is installed correctly.
1
FRU
ADF—jammed media
Action
Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag. Remove any media or debris. If nothing is found, go to step 2.
Diagnostic information 2-113
7002-xxx
FRU
2 ADF exit sensor flag
3
4
ADF exit sensor
Motor driver card
5 ADF exit sensor—electrical checks
Action
Check the exit sensor flag to make sure it operates freely and does not hang or bind. If the flag does not operate correctly and cannot be made to operate correctly, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
If the flag operates correctly, go to step 3.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check the ADF exit sensor for correct operation.
Note: You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF.
If the sensor fails the test, go to step 4.
Turn the power off and disconnect CN9 on the motor driver card.
Measure the voltages in the table below:
Interval sensor—interrupter type
(normally closed)
Connector CN9 (motor driver card)
CN9—Pin 1
CN9—Pin 2
0 V dc
+5 V dc
CN9—Pin 3 +5 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card.
If the voltage is correct, go to step 5.
Turn the power off and reconnect CN9 to the motor driver card.
Measure the voltages in the table below with the sensor in normal operation (sensor closed) and with the sensor open (sensor flag activated).
ADF exit sensor—interrupter type (normally closed)
Connector CN9 (motor driver card)
Pin number
CN9—Pin 1
Sensor closed
0 V dc
Sensor open
0 V dc
CN9—Pin 2
CN9—Pin 3
+1.16 V dc
+5.0 V dc
Note: All voltages are approximate values.
+1.16 V dc
+0.15 V dc
If the voltages are incorrect, replace the ADF exit sensor. If this does not fix the problem, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
2-114 Service Manual
7002-xxx
298.01 Error code service check—models X644e/X646e
Scanner missing—front side cable unplugged.This is the ADF CCD 36 pin ICC cable connected to the ADF
CCD.
1
FRU
ADF CCD cable
Action
Check the cable for correct connections to the flatbed interface connector on the rear of the flatbed scanner assembly and to the
ADF CCD assembly. If incorrect, install the cable correctly. If correct, replace the following FRUs in the order shown:
• ADF CCD cable.
• Flatbed interconnect card. See
“Flatbed interconnect card removal” on page 4-33
• ADF CCD assembly.
• If ADF CCD assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4
.
298.02 Error code service check
Scanner missing—rear side cable unplugged. This is the MDC 36 pin ICC cable connected to the motor driver card.
1
FRU
MDC cable
Action
Check the cable for correct connections to the flatbed interface connector on the rear of the flatbed scanner assembly and to the motor driver card. If incorrect, install the cable correctly. If correct, replace the following FRUs in the order shown:
• MDC cable.
• Flatbed interconnect card. See
“Flatbed interconnect card removal” on page 4-33
• Motor driver card.
842.xx Error code service check
Service Scanner
—scanner communications failure.
FRU
1 Scanner control card to flatbed inteconnect card cable
2 Motor drive card to flatbed interconnect card cable
3 Motor driver card
Flatbed interconnect card
Action
Check for correct installation of the scan control to flatbed interconnect card cable.
Check for correct installation of the motor driver card to flatbed interconnect card cable.
If the cables are good and are properly connected, replace the following FRUs in the order shown:
• Flatbed interconnect card assembly
• Motor driver card assembly
Diagnostic information 2-115
7002-xxx
843.xx Error code service check
Service Scanner—flatbed mechanical failure
Other symptoms may include a loud noise from between the flatbed and the printer unit, or a blue screen on the display.
Note: Check for correct installation of the home sensor cable before proceeding with this service check.
FRU
1 Flatbed scanner CCD drive shafts
2 Flatbed CCD module assembly ribbon cable
3 Flatbed CCD module assembly
4 Flatbed CCD scan motor/ cable
Flatbed interface card
5 Flatbed home sensor cable
Flatbed home sensor
Flatbed interface card
Action
Check to make sure that both of the CCD drive shafts are correctly installed. If correct, go to step 2.
Check to make sure that the flatbed CCD module assembly is connected correctly to both the CCD module and J2 on the scanner control card. If correct, go to step 3.
Check the flatbed CCD assembly for any signs of damage and for proper mechanical operation. If any problems are found, replace the flatbed CCD assembly.
If the flatbed CCD assembly is replaced, it is necessary to perform
scanner registration. See “Scanner registration” on page 4-4 .
Check for correct installation of the CCD scan motor cable to both the motor and to the flatbed interface card at CN2.
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Feed Tests .If the motor does not turn during the scanner Feed Test, check for any signs of binds or mechanical problems. Repair as necessary. If no problem is found, go to step 5.
Check to make sure that the home sensor cable is correctly installed to both the home sensor and to CN4 on the flatbed interface card.
Check for correct operation of the home sensor. If it does not operate correctly, replace the FRUs in the following order:
• Flatbed interface card. See
“Flatbed interconnect card removal” on page 4-33
.
• Flatbed home sensor. See “Home sensor removal” on page 4-46 .
If the problem persists, go to step 6.
2-116 Service Manual
7002-xxx
FRU
6 Mechanical interference with the flatbed CCD assembly
Action
Check for mechanical interference with the flatbed CCD assembly and the metal locating bracket. Remove the glass slit. See
“Scanner flatbed glass holder assembly removal” on page 4-50 . The
bracket is located near the home position, to the left side of the flatbed.
1. Move the flatbed CCD assembly a few inches to the right of home.
2. Bend the bracket upwards 1–2 mm.
3. Move the flatbed CCD assembly back to the home position and check for clearnace between the bracket and the edge of the flatbed CCD assembly.
7 Flatbed scanner assembly
If this does not fix the problem, got to step 7.
If the 843.00 error code continues to be displayed, replace the
complete flatbed scanner assembly. See “Flatbed scan assembly removal” on page 4-38
.
Note: If the flatbed scanner assembly is replaced, it is necessary to
perform scanner registration. See “Scanner registration” on page 4-4
.
845.00 Error code service check
Service Scanner—this error indicates a failure of the image processing ASIC on the scanner control card.
1
FRU
Scanner control card
Action
Replace the scanner control card. See
“Scanner control card removal” on page 4-48
.
Diagnostic information 2-117
7002-xxx
848.00 Error code service check
Service scanner—Modem/Config ID mismatch
This error indicates that no modem is installed on a modem MFP.
1
FRU
Modem
1
FRU
Modem
Action
Install a modem.
848.01 Error code service check
Service scanner—Modem/Config ID mismatch. This error indicates that a mode is present on an MFP not configured to support a modem.
Action
Remove the modem installed in the printer.
900.xx Error code service check
1
FRU
Printer POR
2 System board
3 Factory defaults
4 Sub error codes
Action
Turn the printer off and on several times. If Error Code 900 continues to display, go to step 2.
Turn the machine off and on several times, waiting a few minutes between power on and power off.
If Error Code 900 continues to display, go to step 3.
Restore factory defaults. See
. This resets the non-critical areas of the user NVRAM. If Error Code 900 continues to display, go to step 4.
With Error Code 900 displayed, press and 2 . Record the complete list of Sub Error Codes on the display, then call your next level of support or call Lexmark.
900.90 Error code service check
Service scanner—
This error indicates defective modem hardware.
1
FRU
Modem
Action
Replace the modem.
2-118 Service Manual
7002-xxx
927.xx Fan service check
927.xx can be used for the main fan or the cartridge fan.
•
Main fan—927.00, 927.01, and 927.03 through 927.07.
•
Cartridge fan—927.02
Main fan service check
Service tip: The main fan runs at full speed at the end of POR or when the printer is printing. It will only run half speed when the printer is in the Ready state and not printing.
FRU Action
1
2
Main fan
Main fan
3 Main fan blades turn during
POR, then stop. Fan will not run when trying to print.
Main fan
System board
Check the main fan to make sure it is plugged into J4 on the system board. If the fan cable id correctly connected to J4, check the cable and the cable connector for any signs of damage. If damaged,
replace the main fan assembly. See “Main fan removal” on page 4-111 . If undamaged, go to step 2.
Turn the printer off and check the main fan for any signs of blockage of the fan blades. If there is any sign of blockage, remove the blockage.
Measure the voltage at J4-1 on the system board. The voltage should measure approximately +2.5 V dc. If incorrect, replace the main fan. See
“Main fan removal” on page 4-111 .
If that does not fix the problem, replace the system board. See
“System board and inner shield removal —models X644e/
.
4 Main fan blades do not turn Measure the voltage at J4-3. The voltage should measure +14.4 V dc with the fan running full and approximately 7.0 V dc when running
system board. See
“System board and inner shield removal — models X644e/X646e” on page 4-131 .
Cartridge fan service check
Error code 927.02 indicates a problem with the cartridge fan.
1
FRU
Cartridge fan
2 Cartridge fan
3 Cartridge fan
System board
Action
Check to make sure the cartridge is plugged into J5 on the system board. If properly plugged in, go to step 2.
Check for any signs of blockage in the fan. If any is found, remove and retry the printer. If no problem is found, go to step 3.
Replace the following FRUs in the order shown:
• Cartridge fan
• System board. See
“System board and inner shield removal
—models X644e/X646e” on page 4-131 .
Diagnostic information 2-119
7002-xxx
950.00 through 950.29 EPROM mismatch failure
Warning: When replacing any one of the following components:
• Flatbed interconnect card (ICC)
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
This error code indicates a mismatch between the operator panel board and the interface card.
1
FRU
Interface card
2 Operator panel board
3 Interface card
4 Operator panel board
5 Interface card
6 Operator panel
Action
If the interface card been recently replaced, go to step 3. If the card has not been replaced go to step 2.
If the operator panel board has been recently replaced, go to step 4.
If the operator panel board has not been replaced, contact your next level of support.
Replace the current interface card assembly with the original interface card assembly. See
“Interface card assembly removal” on page 4-107 .
If the error remains, go to step 5.
Replace the current operator panel board with the original operator panel board. See
“Operator panel right cover assembly removal” on page 4-64
.
If the error persists, go to step 6.
Replace the original interface card assembly with a new and not previously installed interface card assembly. If the error remains, contact your next level of support.
Replace the original operator panel board with a new and not previously installed interface card assembly. If the error remains, contact your next level of support.
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7002-xxx
950.30 through 950.60 EPROM mismatch failure
Warning: When replacing any one of the following components:
• Flatbed interconnect card (ICC)
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
Note: Before proceeding with this service check, make sure you have the correct system board installed in the printer. The system board has a label with an board ID and barcode. Use the first eight numbers to identify the board with the part number in the table below:
Model Board bar code Corresponds to P/N…
Lexmark X642e (003, 004, 005, 006) M010 6030
Lexmark X644e/X646e (001, 002, 011, 012, 101, 102, 111, 112) M010 6000
40X3310
40X2722
This error code indicates a mismatch between the system board and the interface card.
1
FRU
Interface card assembly
2
3
4
5
System board
Interface card assembly
System board
Interface card assembly
Action
If the interface card assembly has been recently replaced, go to step
3. If the interface card assembly has not been recently replaced, contact the next level of support.
If the system board has been recently replaced, go to step 4. If the system board has not been replaced, contact the next level of support.
Replace the current interface card assembly with the original interface card assembly. See
“Interface card assembly removal” on page 4-107 . If the error remains, go to step 5.
Replace the current system board with the original system board.
See “System board and inner shield removal —models X644e/
.
If the error remains, go to step 6.
Replace the original interface card assembly with a new and not previously installed interface card assembly. If the problem remains, contact the next level of support.
Diagnostic information 2-121
7002-xxx
FRU
6 System board
Action
Replace the original system board with a new and not previously installed system board. If the problem remains, contact the next level of support.
ADF paper length sensor service check—models X644e/X646e
Note: There are two cables between the motor driver card and the paper length sensor. Check to make sure both cables are installed correctly.
1
FRU
ADF paper length sensor
(in ADF paper tray)
2 ADF paper length sensor
Motor control card
3 ADF paper length sensor
Action
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check the ADF paper length sensor for correct operation by putting a sheet of paper in the tray over the sensor. If the sensor does not operate properly, go to step 2.
Turn the power off, and disconnect the cable to CN8, and measure the voltages at CN8 on the card. Measure the voltages shown in the table below:
Paper length sensor—reflective type
(normally closed)
Connector CN8 (motor driver card)
CN8—Pin 4
CN8—Pin 5
0 V dc
+5 V dc
CN8—Pin 6 +5 V dc
Note: All voltages are approximate values.
If incorrect, replace the motor driver card. If correct, go to step 3.
Turn the power off and reconnect CN8 to the motor driver card.
Measure the voltages in the table below:
Interval sensor—reflective type (normally closed)
Connector CN8 (motor driver card)
Pin number Sensor closed
CN8—Pin 4
CN8—Pin 5
0 V dc
+0.03 V dc
CN8—Pin 6 +5.0 V dc
Note: All voltages are approximate values.
Sensor open
0 V dc
+5.0 V dc
+5.0 V dc
If the voltages are incorrect, replace the paper length sensor. If this does not fix the problem, replace the ADF paper tray assembly.
If the problem persists, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
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7002-xxx
ADF paper width sensor service check—models X644e/X646e
Note: There are two cables between the motor driver card and the paper width sensor. Check to make sure both cables are installed correctly.
1
FRU
ADF paper tray
Action
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check the ADF paper width sensor for correct operation by moving the paper width guides on the paper tray in and out. If only one or two of the sensor widths does not operate properly, replace the ADF paper tray assembly. If none of the sensors operate correctly, replace the ADF paper tray. If this does not fix the problem, replace the motor driver card.
Charge roll service check
Service tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 in.) apart, or spots on the page can be caused by a damaged or contaminated dual charge roll.
Service tip: Make sure the right charge roll arm bushing is correctly installed and operates correctly.
To remove the charge roll:
1.
Wrap a piece of plain white paper around the charge roll to prevent contamination or damage.
2.
Carefully remove the roll by pressing outward and to the right on the charge roll link arm, and remove the charge roll from the right side charge roll bearing.
3.
Remove the charge roll from the left side charge roll bearing, and remove the roll from the printer. Leave the paper wrapped around the charge roll until it is reinstalled.
1
FRU
Charge roll assembly
2 Left side charge roll link
3 Right side charge roll link
Right charge roll bushing
Action
Check the charge roll for correct installation, toner buildup, marks, cuts, or other signs of contamination or damage. Replace as necessary.
Check the left side charge roll link assembly for correct assembly operation. Check for damage to the arm or bearing assembly.
Check the right side charge roll link assembly for correct assembly operation. If incorrect, replace the charge roll link assembly with the charge roll link assembly kit. If correct, check the right charge roll link assembly bearing for signs of wear or contamination. Excessive contamination could cause intermittent charging of the charge roll. If incorrect, replace the link assembly. Check for continuity of the right link assembly from the bearing to the charge roll high voltage contact on the right side frame. If incorrect, replace the link assembly.
Make sure the charge roll bushing is installed and operating correctly.
Note: The screw that attaches the charge roll lead to the contact must be secure.
Diagnostic information 2-123
7002-xxx
Cover closed sensors service check—flatbed
Note: Check for correct installation of the sensor cable before proceeding with this service check.
Note: Both the cover closing sensor (A) and the cover closed (B) sensor are located in the ADF assembly.
A B
1
FRU
Flatbed cover closing and flatbed cover closed sensors
2 Flatbed closed and flatbed closing actuators
3 Flatbed cover closed and closing sensors
4 Flatbed cover closing/ closed sensors cable
Action
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check for correct operation of the senors by opening and closing the ADF scanner assembly. If incorrect, go to step 2.
Check the flatbed actuators for any signs of a broken, damaged, or missing part. Replace either actuator if damaged or missing.
Turn the power off, disconnect the cable to CN7, and measure the voltages at CN7 on the card. The voltages should measure as shown in the table below:
Paper length sensor—reflective type
(normally closed)
Connector CN7 (motor driver card)
CN7—Pin 1
CN7—Pin 2
CN7—Pin 3
CN7—Pin 4
0 V dc
+5 V dc
+5 V dc
0 V dc
CN7—Pin 5
CN7—Pin 6
+5 V dc
+5 V dc
Note: All voltages are approximate values.
If any of the voltages are incorrect, replace the motor driver card. If the voltages are correct, go to step 4.
Check continuity of the flatbed cover closing/closed sensor cable. If incorrect, replace the complete ADF assembly.
“ADF complete assembly removal” on page 4-15 .
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform scanner registration. See
“Scanner registration” on page 4-4 .
If correct, replace the failing sensor.
2-124 Service Manual
7002-xxx
Cover closed switch/cable service check—printer
1
FRU
Toner cartridge
2 Cover closed switch/cable assembly
Action
Make sure the toner cartridge is correctly installed and that the right and left cartridge tracks are not loose or broken. Make sure the cover closed switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover closed switch spring.
Check the cover closed switch for proper mechanical operation. If incorrect, repair as necessary. Disconnect the cover closed switch cable from J8 at the system board and measure the voltage at J8-3.
It measures approximately +5 V dc. If the voltage is incorrect, replace the system board. If the voltage is correct, check the voltage at J8-1.
If the voltage measures greater than +1.0 V dc, replace the system board. If the voltage is correct, check the continuity between J8-1 and J8-3 on the cable. If no change in continuity occurs as the switch is activated, replace the hinge assembly. If the continuity changes as the switch is activated, replace the system board.
Cover closed switch table
J8
Pin number
Pin 1-3
Pin 1-2
Cover open
Open
Closed
Switch status
Cover closed
Closed
Open
Dead machine service check
A dead machine is a condition where the LCD touchscreen is blank, the LED on the operator panel right cover is off, no fans turn, no motors turn, and the fuser lamp does not come on.
If a high-capacity input tray is installed, remove the option and check the printer for correct operation. If the printer operates correctly, go to
“High-capacity feeder input tray service check” on page 2-141
. If the printer continues to not operate correctly, remove any other attached paper handling options.
Warning: Observe all necessary ESD precautions when removing and handling the system board or any installed option cards or assemblies. See
“Handling ESD-sensitive parts” on page 4-1
.
CAUTION
When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Remove any input and output paper handling options from the printer.
1
FRU
Line voltage
2 AC line cord
Action
Check the AC line voltage. If the line voltage is incorrect, inform the customer.
Unplug the line cord from the wall outlet and check the line cord for damage, such as, a damaged plug, or cut or damaged cord. If incorrect, replace the cord. If incorrect, check the continuity of the line cord and replace if necessary. If the cord is correct, go to step 3.
Diagnostic information 2-125
7002-xxx
FRU
3 +5 V dc test point on the system board
Action
Check for approximately +5 V dc at the +5 V test point on the system board.
Note: Use care not to short adjacent voltage test points.
4 System board
5 LVPS
If the voltage is correct, Go to step 9. If the voltage is incorrect, go to step 4.
Check to make sure the LVPS cable is correctly installed at J27 on the system board. If not, reseat and recheck the voltage at the
+5 V dc test point on the system board.
If test point does not measure +5 V dc, go to step 5.
Unplug the AC line cord from the LVPS and disconnect the LVPS cable to the system board. Reconnect the AC line cord and measure the voltage on CN2-1 on the LVPS. The voltage should measure approximately +5 V dc.
6 Features or option installed on the interface card assembly
7 LVPS fuse F1 (primary power)
If the voltage is correct, go to step 6. If the voltage is incorrect, replace the LVPS assembly. See
“Low voltage power supply removal” on page 4-109
Warning: Observe all the ESD precautions and turn the printer off before any feature or option cards are removed or replaced.
Remove one option/feature at a time to help isolate the failing part.
Replace the faulty part.
Unplug the AC line cord, remove the LVPS from the printer, and check the continuity of fuse F1. See
“Low voltage power supply removal” on page 4-109 .
If continuity is correct, replace the LVPS assembly.
8 Loads connected to the system board
9 Interface card
Scanner control card
Turn the printer off and disconnect each cable connected to the system board and each option installed on the system board until the problem is located.
Warning : When removing any card installed on the system board observe all ESD precautions when handling these options.
Check for the correct installation of the interface card to the printer system board and to the scanner control card. If correct, go to step
10.
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7002-xxx
FRU
10 System board
Scanner control card
Interface card
Action
Replace the following FRUs in the order shown one at a time in until the problem is fixed:
• Scanner control card. See
“Scanner control card removal” on page 4-48 .
• System board. See
“System board and inner shield removal
—models X644e/X646e” on page 4-131 .
• Interface card. See
“Interface card assembly removal” on page 4-107
.
Duplex option service check
Duplex paper jams
23x.xx jam code
231.xx
232.xx
233.xx
234.xx
235.xx
236.xx
237.xx
238.xx r
Jam location
Media did not arrive at the duplex input sensor, but did leave the fuser exit sensor.
Media did not clear the duplex input sensor, but did leave the printer fuser exit sensor.
Media failed to make the duplex double feed sensor during turnaround.
Media did not arrive at the duplex exit sensor.
A piece of media is over the duplex double feed sensor.
Media did not leave the duplex exit sensor.
A duplexed sheet did not reach the printer input sensor.
A piece of media is over the duplex sensors during a reset.
Duplex does not recognize that the option is installed, or other options below the duplex are installed
1
FRU
Autoconnect cables/ connections
Action
Check the top and bottom autoconnect connectors for signs of damage. If damaged, replace the duplex option. If not damaged, check the cables are correctly connected to the duplex system board at J9, J10, J11, and J12. If no problem is found, replace the duplex option.
Note: Before proceeding with the following service checks, verify the media used in the duplex option meets specification and is not dog-eared or damaged in any way. See
“Media specifications” on page 1-9 .
Diagnostic information 2-127
7002-xxx
231.xx Jam displays
1
FRU
Fuser exit sensor
2 Duplex input sensor
Action
Check the sheet of media is leaving the exit sensor in the fuser and feeding properly into the duplex option. Check the duplex link for correct operation and any signs of damage. If the problem is prior to the duplex input sensor and in the base machine, repair as necessary. If the jam occurs in the duplex option prior to the duplex input sensor, go to step 2.
If the paper does not reach the duplex input sensor, make sure the sensor is connected to the duplex system board. If correct, check for any paper or other objects that might cause a paper jam. If none are found, replace the duplex option assembly.
232.xx Jam displays
1
FRU
Duplex input sensor
Action
If the paper reaches the duplex input sensor, but does not clear the sensor, make sure the sensor is connected to the duplex system board. If connected correctly, check for correct operation of the sensor. If a problem is found and cannot be corrected, replace the duplex option assembly. If no problem is found, check for a piece of paper or other object in the paper path that might cause a paper jam over the input sensor. If no problem is found, replace the duplex option assembly.
233.xx Jam displays
1
FRU
Duplex double feed sensor
Action
If a sheet of paper fails to reach the double feed sensor during turnaround, check for any signs of paper or other objects that might cause the paper to jam. If no problem is found, replace the duplex option assembly.
2-128 Service Manual
7002-xxx
Envelope feeder service check
Service tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If any other options are installed make sure they are operating normally. If only the envelope feeder is failing to operate correctly, continue with this service check, otherwise verify the interconnect card is functioning properly.
Service tip: The envelope feeder receives its +5 V dc operating voltage from the +24 V dc bulk at J1-7. If
+24 V dc is not present at J1-7, tray 1 is the only tray that is recognized.
Printer does not recognize the envelope feeder as an attached input option
1
FRU
Envelope feeder
2 Front autoconnect on printer
3 Autoconnect on the envelope feeder
Action
Make sure the envelope feeder is correctly installed and mated to the autoconnect at the front of the printer.
Check the connector for signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Remove the envelope feeder and check the voltages at the autoconnect on the front of the printer. If incorrect, check the system board. If correct, reinstall the envelope feeder and continue with step 3.
Check for damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages:
• J1-3 measures +5 V dc
• J1-5 measures +5 V dc
• J1-7 measures +24 V dc
If any of the voltages are incorrect, replace the autoconnect cable/ connector. If the voltages are correct, replace the envelope system board.
Touchscreen displays 260.xx Paper Jam immediately when envelope feed is requested—
POST incomplete
1
FRU
Pass thru sensor
Action
Check for any debris or pieces of envelope over the pass thru sensor. Check for correct installation of the pass thru sensor flag.
Make sure the sensor cable is attached to the envelope system board. Perform an envelope feeder sensor test to check both the sensor and sensor flag.
Note: It may be necessary to use a small tool to actuate the sensor flag because it is located under the front cover. Be careful not to damage the flag.
If the test fails, check the flag for damage or binds. If incorrect, replace the flag. If the flag is operating correctly, check the voltage at
J3-3. The voltage measures approximately +5 V dc. If incorrect, replace the envelope system board. If correct, check the voltage at
J3-2. The voltage changes from 0 to +5 V dc when the flag is moved in and out of the sensor. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the envelope system board.
Diagnostic information 2-129
7002-xxx
Touchscreen displays 260.xx Paper Jam after attempted feed but before envelopes are put in the hopper OR the touchscreen continues to display Load Envelopes after envelopes are placed in the hopper
Service tip: The kick rolls rotate during the attempted feed cycles.
1
FRU
Envelope out hopper sensor flag
Action
Check the envelope out sensor flag for damage, correct installation and operation.
If incorrect, repair or replace the envelope feeder option.
990.xx Service Error, envelopes fail to feed from the hopper
1
FRU
DC feed motor assembly
Action
Check the motor and motor cable for loose wires or poor connections. Make sure the motor cable is connected to the envelope system board.
If correct, replace the envelope feeder option.
260.xx Paper Jam displays, unable to clear and envelopes fail to feed from the hopper—
Kick rolls are not rotating
1
FRU
Clutch latch assembly
Action
Check the clutch latch assembly to make sure it moves freely.
If correct, replace the envelope feeder option.
260.xx Paper Jam displays, unable to clear and envelopes fail to feed from the hopper
Kick rolls are rotating.
Check the deflector gap adjustment before continuing this service check.
1
FRU
Deflector gap adjustment
2 Weight assembly
3 Envelope edge guide
Action
Check the deflector gap adjustment. The adjustment may be too narrow.
Check the weight assembly to make sure it moves up and down freely without any binds. Make sure the weight assembly rests on all the rear kick rollers when the hopper is empty. If the weight assembly is damaged or does not operate properly, replace the envelope feeder assembly.
Check the envelope edge guide to make sure it is not warped or set too close to the envelopes in the hopper. If the edge guide is damaged or does not operate properly, replace the envelope feeder option.
2-130 Service Manual
7002-xxx
260.xx Paper Jam displays, envelope stops in feeder paper path
1
FRU
Kick rolls/feed rolls/drive rolls
2 Deflector gap adjustment
Action
Check all the rolls for oil, grease, or other contamination. If you find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder.
Check the deflector gap adjustment. The adjustment may be too narrow. If the adjustment is correct, replace the envelope feeder option.
Envelope feeder multifeeds or may not display a 260.xx Paper Jam message
1
FRU
Envelopes
2 Deflector
3 Restraint roll bias spring
Action
Check the envelopes being used in the feeder. Check for signs of the envelopes being stuck together or signs of glue. Make sure the flaps are not interleaved.
If the envelopes meet the guidelines and are properly loaded, go to step 2.
Check the deflector gap adjustment. The adjustment may be too wide.
If the deflector gap adjustment is correct, go to step 3. If not, replace the envelope feeder option.
Check for a missing, broken or incorrectly installed restraint roll bias spring. If incorrect, replace the envelope feeder option.
260.xx Paper Jam displays, an envelope stopped in the paper path of the feeder and an envelope also stopped in the printer paper path
1
FRU
Latch lever
Action
Make sure the tip of the latch lever is centered in the opening in the floor of the paper path. The latch lever may not be detented on the latch. If no problem is found and the problem persists, replace the envelope feeder option.
Flatbed size sensor service check
Check for correct installation of the sensor cable before proceeding with this service check.
Note: All three sensors and their cables come attached together as a unit.
1
FRU
Flatbed paper size sensor assembly
Flatbed interface card assembly
Action
Enter the Diagnostics Menu (turn on MFP while holding 3 and 6 ), select SCANNER TESTS , and select Sensor Tests . Check for correct operation of the sensors by placing a piece of paper on the contact glass over the sensor assembly. If any sensor fails the sensor test, replace the sensor assembly. If this does not fix the problem, replace the flatbed interface card. See
“Flatbed interconnect card removal” on page 4-33
.
Diagnostic information 2-131
7002-xxx
Fuser service checks
920.xx—Cold fuser service check
Error codes 920.x and 922.xx may display for a cold fuser failure.
Some 920.xx error codes may be cleared by turning the printer on and off and allowing it to complete POR.
CAUTION
There is a danger from hazardous voltage in the area of the product where you are working.
Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Service tip: Some 920.xx errors can be caused by multiple sheets of paper being fed up to the fuser.
Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, select EP SETUP , and Fuser Temp .
Service tip: It may take several minutes for the error codes 920.xx and 922.xx to be displayed after the printer is turned on.
1
FRU
Fuser lamp
Fuser lamp AC cable
2 AC line voltage
3 LVPS
Action
Observe the lamp through the left near side of the printer. It may be necessary to remove the redrive assembly to observe the lamp turning on and off. If the lamp does not come on do the following:
• If not previously removed, remove the redrive assembly. See
“Redrive assembly removal” on page 4-128 .
• Remove the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
• Make sure the correct type of lamp is installed (voltage and wattage).
• Verify that the fuser to fuser lamp cable is installed correctly to the fuser top cover assembly. If incorrect, install correctly; if correct, go to step 2.
CAUTION : When taking measurements for AC power, observe all safety precautions.
Check the AC line voltage to make sure it is within operating specification. If incorrect, inform the customer; if correct, go to step 3.
CAUTION : When taking measurements for AC power, observe all safety precautions.
Unplug the AC line cord from the printer and pull the LVPS out far enough to access CN1 on the LVPS board (see
“Low voltage power supply removal” on page 4-109 ). Disconnect the LVPS to
fuser AC cable, plug in the line cord, turn the printer on and measure the voltage between CN1-1 and CN1-3 on the connector (see the
connector locations at “Low voltage power supply” on page 5-11 ).
If incorrect, replace the LVPS assembly (see
“Low voltage power supply removal” on page 4-109
); if correct, go to step 4.
2-132 Service Manual
7002-xxx
FRU
4 Fuser lamp
Fuser top cover assembly
Fuser connect cable (fuser to fuser lamp cable)
5
6 Fuser top cover assembly
(thermistor, thermistor
7
8
LVPS
LVPS to fuser AC cable cable)
Fuser to system board DC cable
Error code 920.06
displayed
LVPS
System board
System board to LVPS cable
Fuser assembly
Action
Check continuity of the fuser to fuser AC cable, fuser top cover assembly, and fuser lamp by checking the continuity between the two pins on the fuser lamp AC cable connector:
• If there is continuity, go to step 5.
• If there is no continuity, check the continuity of the fuser to fuser lamp AC cable. If incorrect, replace the lamp, if incorrect, replace the fuser top cover assembly.
Note: If the fuser lamp is replaced, allow the fuser assembly to cool or a 925.xx error may be displayed.
CAUTION : When taking measurements for AC power, observe all safety precautions.
Check the AC line voltage between the pins on the fuser end of the
LPVS to fuser AC cable. If the voltage is correct, unplug the AC power cord from the LVPS cable. If the voltage is correct, unplug the
AC power cord from the LVPS, pull the LVPS out far enough to be able to check the voltage between CN-1 and CN1-3 on the LVPS board. Plug in the power cord, turn the printer on and check the voltage. If correct, replace the LVPS to fuser AC cable; if incorrect, replace the LVPS assembly.
Note: If the fuses in the LVPS are blown, the LVPS assembly must be replaced.
Check to make sure that the thermistor is installed correctly to J5 on the fuser control card. If installed correctly check the cable for any signs of damage. If any problems are found, replace the fuser top cover assembly. If no problem is found, check the fuser to system board DC cable for correct installation at J1 on the fuser control card.
If no problem is found, check the fuser to system board cable for correct installation at J10 on the system board.
Carefully check the installation of the LVPS to system board cable to
J27 on the system board and to CN2 on the LVPS. If the cable is not seated or installed properly, reseat the cable and retry the printer. If the cable is installed correctly, replace the following FRUs in the order shown:
• LVPS assembly. See
“Low voltage power supply removal” on page 4-109
.
• System board assembly. See
“System board and inner shield removal —models X644e/X646e” on page 4-131
.
• LVPS to system board cable.
If no problem is found up to this point, then replace the following in the order shown:
• Fuser assembly. See
“Fuser assembly removal” on page 4-79
.
• System board assembly. See
“System board and inner shield removal —models X644e/X646e” on page 4-131
.
• LVPS. See “Low voltage power supply removal” on page 4-109
.
Diagnostic information 2-133
7002-xxx
922.xx—Cold fuser check
Error codes 920.xx and 922.xx may display for a cold fuser failure.
Some 920.xx error codes may be cleared by turning the printer on and off and allowing it to complete POR.
CAUTION
There is a danger from hazardous voltage in the area of the product where you are working.
Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, select EP SETUP , and Fuser Temp .
1
FRU
Fuser lamp
2 AC line voltage
3 LVPS
4 LVPS
LVPS fuser AC cable
Action
Remove the fuser assembly and check to make sure the correct fuser lamp has been installed. If the correct lamp has been installed, go to step 2.
Note: If the fuser lamp is replaced, allow the fuser assembly to cool or a 925.xx error code could be displayed.
CAUTION : When taking measurements for AC power, observe all safety precautions.
Check the AC line voltage to make sure it is within operating specification. If incorrect, inform the customer; if correct, go to step 3.
CAUTION : When taking measurements for AC power, observe all safety precautions.
Unplug the AC line cord from the printer and pull the LVPS out far enough to access CN1 on the LVPS board (see
“Low voltage power supply removal” on page 4-109 ). Disconnect the LVPS to
fuser AC cable, plug in the line cord, turn the printer on and measure the voltage between CN1-1 and CN1-3 on the connector (see the
connector locations at “Low voltage power supply” on page 5-11 ).
If incorrect, replace the LVPS assembly (see
“Low voltage power supply removal” on page 4-109
); if correct, go to step 4.
CAUTION : When taking measurements for AC power, observe all safety precautions.
Disconnect the AC line cord from the printer. Disconnect the LVPS to fuser cable from the fuser to fuser lamp cable. Plug the AC line cord into the printer and check the AC line voltage between the pins on the fuser end of the LVPS to fuser AC cable. If the voltage is correct, unplug the AC power cord from the LVPS cable and pull the LVPS out far enough to be able to check the voltage between CN-1 and
CN-3 on the LVPS board. Plug in the power cord, turn the printer on and check the voltage. If correct, replace the LVPS to fuser AC cable;
if incorrect, replace the LVPS assembly. See “Low voltage power supply removal” on page 4-109
.
Note: If the fuses in the LVPS are blown, the LVPS assembly must be replaced.
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FRU
5 Fuser top cover assembly
(thermistor, thermistor cable)
Fuser to system board DC cable
6 Fuser assembly
Action
Check to make sure that the thermistor is installed correctly to J5 on the fuser control card. If installed correctly check the cable for any signs of damage. If any problems are found, replace the fuser top
“Fuser narrow media sensor removal” on page 4-88
.
If no problem is found, check the fuser to system board DC cable for correct installation at J1 on the fuser control card. If no problem is found, check the fuser to system board cable for correct installation at J10 on the system board. If no problem is found, go to step 6.
If no problem is found up to this point, then replace the following in the order shown:
• Fuser assembly. See
“Fuser assembly removal” on page 4-79
.
• System board assembly. See
“System board and inner shield removal —models X644e/X646e” on page 4-131
.
• LVPS. See “Low voltage power supply removal” on page 4-109
.
923.xx—Hot fuser service check
Error Code 923.xx, 924.xx, and 925.xx may display for a hot fuser failure.
CAUTION
The fuser may be hot, use caution before removing or servicing.
CAUTION
There is a danger from hazardous voltage in the area of the product where you are working.
Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, In
Diagnostics mode, select EP SETUP , and Fuser Temp .
1
FRU
Fuser assembly
2 Fuser top cover assembly
(thermistor)
3 System board
Fuser top cover assembly
Action
Check for any signs of overheating in the fuser assembly. Check the hot roll, hot roll bearings, and the area around the thermistor for any signs of excessive heat. If a problem is found, replace the thermistor.
If no problem is found, go to step 2.
Turn the printer off and disconnect the fuser to system board cable from J10 on the system board. Check the resistance between pins
J10-3 and J10-4. The resistance should be greater than 100K ohms.
If correct, go to step 3; if incorrect, disconnect the thermistor cable from J5 on the fuser board and measure the resistance between the two pins on the thermistor cable. If incorrect, replace the fuser top cover assembly (see
“Fuser narrow media sensor removal” on page 4-88
); if correct, replace the fuser to system board cable.
Check the voltage on J10-3 ground on the system board. The voltage should measure approximately +3.3 V dc. If the voltage is correct, replace the fuser top cover assembly. See
“Fuser narrow media sensor removal” on page 4-88
. If incorrect, replace the system board. See
“System board and inner shield removal —models
Diagnostic information 2-135
7002-xxx
924.xx—Hot fuser service check
Error Code 923.xx, 924.xx, and 925.xx may display for a hot fuser failure.
CAUTION
The fuser may be hot, use caution before removing or servicing.
CAUTION
There is a danger from hazardous voltage in the area of the product where you are working.
Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, In
Diagnostics mode, select EP SETUP , and Fuser Temp .
FRU
1 Fuser assembly
Fuser to system board cable
2 Fuser top cover assembly
(thermistor/thermistor cable assembly)
3 Fuser to system board cable.
System board
Fuser assembly
Action
Check the thermistor cable for correct installation to J5 on the fuser card. If installed correctly, check for correct installation of J10 on the system board. If all cables are installed correctly, go to step 2.
Turn the printer off and disconnect the thermistor cable from J5 on the fuser board. Measure the resistance between the two pins on the thermistor cable, if the resistance measures infinity (open circuit), replace the fuser top cover assembly.
Reconnect the thermistor cable to J5 on the fuser board. Disconnect the fuser to system board cable from J10 on the system board and measure the resistance between J10-3 and J10-4 on the cable. If the resistance measures infinity (open circuit) check the continuity of pins 3 and 4 of the cable. If correct, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 . If incorrect, replace the
fuser to system board cable.
Note: If the error code still displays, replace the system board. See
“System board and inner shield removal —models X644e/
.
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925.xx—Hot fuser service check
Error Code 923.xx, 924.xx, and 925.xx may display for a hot fuser failure.
CAUTION
The fuser may be hot, use caution before removing or servicing.
CAUTION
There is a danger from hazardous voltage in the area of the product where you are working.
Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Service tip: Set the Fuser Temperature to NORMAL before starting this service check. In Diagnostics mode, In
Diagnostics mode, select EP SETUP , and Fuser Temp .
1
FRU
Fuser lamp
2 AC power source
Action
If the fuser is 220 V machine a 115 V fuser may be installed.
If the printer is not a 115 V model, then go to step 2.
If the printer is a 220 V model, then check to make sure that the correct lamp is installed.
Note: If the fuser lamp is replaced, allow the fuser to cool or a 925.xx error could be displayed.
Check the AC power source to make sure it meets specifications. If the AC power source does not meet specifications, inform the customer. If it meets specifications, go to step 3.
3 Fuser lamp Turn the printer off and allow the fuser assembly to cool. After the fuser assembly cools down, turn the printer on. If you receive the
same error code, replace the fuser lamp. See “Fuser lamp removal” on page 4-86
.
Note: If the fuser lamp is replaced, allow the fuser to cool or a 925.xx error could be displayed.
Diagnostic information 2-137
7002-xxx
Fuser exit sensor service check
If any of the following codes are displayed, there is a potential problem in the area of the exit sensor: 201.00,
201.02, 201.10, 201.12, 201.22, 201.30, 201.32, 201.40, 201.41, 201.42, 201.50, 201.52, 201.92, 202.00,
202.02, 202.04, 202.10, 202.11, 202.12, 202.14, 202.20, 202.21, 202,22, 202.24. 202.30, 202.31, 202.32,
202.34, 202.40, 202.41, 202.42, 202.44, 202,50, 202.51, 202.52, 202.54, 202.90, 202.91, 202.92, and 202.94.
Fuser exit and fuser narrow media sensor status chart
Printer not printing— no media over sensors
Exit sensor open
Narrow media sensor open
Printer printing—media over sensor(s), non-narrow media fed through the printer
Printer printing—narrow media fed through the printer
Exit sensor closed
Narrow media sensor closed
Exit sensor closed
Narrow media sensor open
1
FRU
Fuser exit sensor (exit sensor test)
2 Fuser exit sensor cable
3 Fuser exit sensor flag
4 Fuser assembly
Fuser exit sensor cable
Fuser board
Fuser to system board cable
System board
5
Action
Enter the Diagnostic mode, select BASE SENSOR TEST , select the
Exit Sensor to test for proper operation. If the exit sensor fails the test, go to step 2. If the exit sensor passes, go to step 5.
Check the fuser exit sensor cable for correct installation or for any signs of damage to the cable or connectors. If no problem is found, go to step 3. If a problem with the installation is found, install the cable correctly. If damage to the cable or connectors is found, replace the cable.
Make sure the sensor flag is not binding and is operating properly. If the sensor is operating properly, go to step 4. If it is not operating properly, repair or replace the sensor assembly. See
“Fuser exit sensor removal” on page 4-82
.
Check the continuity of the fuser exit sensor cable. If incorrect, replace the cable; if correct check the continuity of the fuser to system board cable. If incorrect, replace the cable; in correct, replace the following FRUs in the order shown:
• Fuser board.
• Fuser assembly. See
“Fuser assembly removal” on page 4-79
.
• System board. See
“System board and inner shield removal
—models X644e/X646e” on page 4-131 .
With the redrive assembly removed from the printer, enter the
Diagnostics mode and run the print test from tray 1 (for example, select PRINT TESTS , Tray 1 , and Continuous ) and observe the media as it passes over the exit and narrow media sensors. Check that the sensor flags are operating correctly. If the sensor flags and hardware are operating incorrectly, repair or replace the failing sensor assembly. If no problem is found, check the fuser for any signs of media in the fuser or any signs of toner or other contamination. If a problem is found, clean or remove the debris or contamination.
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Fuser narrow media sensor service check
If any of the following error codes are displayed, a problem may exist in the area of the narrow media sensor assembly: 201.04, 201.14, 201.24, 201.34, 201.44, 201.54, and 201.94.
Fuser exit and fuser narrow media sensor status check
Printer not printing— no media over sensors
Exit sensor open
Narrow media sensor open
Printer printing—media over sensor(s), non-narrow media fed through the printer
Printer printing—narrow media fed through the printer
Exit sensor closed
Narrow media sensor closed
Exit sensor closed
Narrow media sensor open
1
2
3
FRU
Fuser narrow media sensor
(sensor test)
Fuser narrow media sensor cable
Fuser narrow media sensor flag
4 Fuser assembly
Fuser narrow media sensor cable
5
Fuser board
Fuser to system board cable
System board
Action
Enter the Diagnostics mode, select BASE SENSOR TEST , and select the NM Sensor to test it for proper operation. If the narrow media sensor fails the test, go to step 2; if the narrow media sensor does not pass the test, go to step 5.
Check the fuser narrow media sensor cable for correct installation or any signs of damage to the cable or to the connectors. If no problem is found, go to step 3;. If a problem with the installation is found, install the cable correctly. If damage to the cable or the connectors is found, replace the cable.
Make sure the sensor flag is not binding and is operating properly. If the sensor is operating properly, go to step 4. If the sensor is not operation properly, repair or replace the sensor assembly. See
“Fuser narrow media sensor removal” on page 4-88 .
Check the continuity of the fuser narrow media sensor cable. If incorrect, replace the cable; if correct, check the continuity of the fuser to system board cable. If incorrect, replace the cable; if correct, replace the following FRUs in the order shown:
• Fuser board
• Fuser assembly. See
“Fuser assembly removal” on page 4-79
.
• System board. See
“System board and inner shield removal
—models X644e/X646e” on page 4-131 .
With the redrive assembly removed from the printer, enter
Diagnostics mode and run the printer test from tray 1 and observe the media as it passes over the exit sensor. Check to see that the sensor flag is operating correctly. If the sensor flag and hardware are operating incorrectly, repair or replace the failing sensor assembly. If no problem is found, check the fuser for any signs of media in the fuser or any signs of toner or other contamination. If a problem is found, clean or remove the debris or contamination.
Diagnostic information 2-139
7002-xxx
Fuser solenoid service check
CAUTION
There is a danger from hazardous voltage in the area of the product where you are working.
Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Service tip: Try changing the envelope enhance level setting. A different setting may correct the problem.
Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section
“Fuser solenoid adjustment” on page 4-2
.
1
FRU
Fuser envelope conditioner solenoid
Action
Observe the operation of the fuser solenoid by removing the redrive assembly. Check for proper mechanical operation of the solenoid and associated hardware, link, and so on. If correct, check the resistance of the solenoid between J4-1 and J4-2 on the fuser control board. The resistance measures between 5 ohms and 10 ohms. If
2
3
System board
LVPS
4 Fuser board to system board cable
5 Fuser assembly incorrect, replace the fuser assembly. If correct, go to step 2.
Measure the voltage at the +50 V dc test point on the system board.
The voltage should measure approximately +50 V dc. If incorrect, go to step 3. If incorrect, go to step 4.
Measure the voltage at CN2-18 on the LVPS. The voltage should measure approximately +50 V dc. If incorrect, replace the LVPS assembly. See
“Low voltage power supply removal” on page 4-109 . If correct, replace the system board. See
“System board and inner shield removal—model X642e” on page 4-130 or
“System board and inner shield removal —models X644e/
.
Make sure the cable is connected properly to the system board and fuser control board. Reconnect the cable, if necessary. If the cable is connected correctly, go to step 5.
If no problems were found in steps 1 through 4, replace the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
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High-capacity feeder input tray service check
Note: Voltage measurements in the high-capacity feeder input tray service checks must be made with the highcapacity feeder attached to the printer to obtain accurate results.
Service tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high-capacity feeder tray.
Service tip: Check the other paper sources to be sure they are operating correctly.
The printer indicates a dead machine condition when the high-capacity input tray is installed
1
FRU
AC line cord
AC jumper (HCIT to printer)
AC input and output receptacles
AC wiring harness
Action
If the printer works normally using the AC line cord from the AC wall outlet and does not work when using the AC jumper from the HCIT, check the AC jumper cord. If defective, replace the cord. If not defective, check the AC input and output receptacles and wiring harness in the HCIT. Repair or replace the receptacles or AC wiring harness as required.
Note: Make sure the ground wire is installed correctly from the AC wiring harness to the frame of the HCIT and the nut and lock washer are tightened.
The MFP does not recognize that the high-capacity input tray is installed
1
FRU high-capacity feeder autoconnect mechanical check
2 Printer or option mounted above
3 LVPS
Option system board
Action
Check the high-capacity feeder input tray to make sure it is mounted correctly and is not pushed down into the frame assembly or damaged. Be sure the high-capacity feeder input tray autoconnect is properly connected to the high-capacity feeder tray option board assembly.
Check the option or printer autoconnect for signs of damage. Repair the high-capacity option autoconnect as necessary.
Check the voltages at J11-2 and J11-4. The voltage measures
+24 V dc, If the voltage is correct, replace the high-capacity system board assembly. If the voltage is incorrect, check the continuity of the
AC input cable to the LVPS. If correct, replace the LVPS assembly. If incorrect, replace the AC cable to the input of the LVPS.
Diagnostic information 2-141
7002-xxx
FRU
4 High-capacity feeder option control board
Action
Check the voltage on J8-1 (green). The voltage measures +24 V dc.
If incorrect, check the autoconnect system for any problems.
+24 V dc must come from the printer through the autoconnect system to the high-capacity input for the high-capacity feeder to be recognized. If the voltage is correct, check the voltages at J11-3(red) and J11-4(red). The voltages measure +24 V dc. If correct, replace the high-capacity feeder option system board. If incorrect, disconnect
J8 from the system board and measure the voltages again. If incorrect, check the LVPS cable and the AC internal wiring from the input appliance receptacle. If incorrect, replace as necessary. If correct, replace the LVPS. If the voltages are correct, check the stepper motor for shorts from the motor housing to each pin on the motor connector. If you find a short between any pin and the motor housing, replace the motor assembly. If no shorts are found, replace the high-capacity feeder option control board.
Check the voltage at J9-1 (light blue). The voltage measures approximately +24 V dc. If incorrect, disconnect the cable at J9 and check the voltage again. If the voltage continues to be incorrect, replace the high-capacity feeder option system board. If the voltage measures correctly, check the cable. If the cable is damaged, replace as necessary. If no problem is found with the cable, replace the highcapacity feeder option control board.
24x.xx Paper Jam displays, paper jammed over the pass thru sensor
Where x =the printer displays the value of x for the paper tray where the error occurs. For example: 242.xx is a
Paper Jam Tray 2
1
FRU
Pass thru sensor and flag assembly
2 Power takeoff shaft and spring, bevel gear, feed roll gear, drive roll assembly, wear plate, drive shaft bearings, and skewed backup roller
Action
The tray x option system board did not detect a piece of paper actuating the pass thru sensor. Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu. If the test fails, check the sensor for correct installation and the flag for proper operation. Also check the sensor cable to make sure it is correctly connected to the option system board. If incorrect, replace the tray x option pass thru sensor assembly.
Check these parts for signs of broken or damaged parts, contamination on the drive rollers or wear plate and wear or damage to the drive shaft bearings. Check the drive roll assembly and skewed backup roller for wear, slick spots, material buildup, and oil or grease on the rollers. Also check for proper operation of the paper aligning assembly. Repair or replace parts as necessary.
Tray x Paper Low displays when tray x is full or has adequate paper in the tray
1
FRU
Paper low switch
Paper low switch cable
High-capacity feeder Input system board
Action
Run the sensor diagnostics for tray x ( x =the number that represents the high-capacity input tray). If the test fails, disconnect the paper low switch cable from J3 on the high-capacity system board. Short pins 1 and 2 together while observing the sensor test on the display. If the display does not change, replace the high-capacity feeder system board. If the display changes check the continuity of the switch. If incorrect, replace the switch. If correct, replace the switch cable.
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Tray x Empty displays when there is paper in the high-capacity feeder input tray
FRU
1 Paper out sensor flag
2 Paper out sensor
(on option system board)
Action
Check the paper out sensor flag for correct operation and installation.
If correct, replace the high-capacity feeder system board. (The paper out sensor is mounted on the high-capacity feeder system board.)
The elevator tray fails to stop at the correct position and continues to drive into the bottom frame
1
FRU
Lower limit switch
Lower limit switch cable
2 High-capacity feeder control board
Action
Check continuity of the lower limit switch. If incorrect, replace the switch. If correct, check the switch cable. If incorrect, replace the cable. If correct, replace the high-capacity feeder option control board.
Disconnect the lower limit switch cable and check the voltage at J2-1
(orange). The voltage measures approximately +5 V dc. If incorrect, replace the high-capacity feeder option control board.
The elevator tray down button does not operate. The tray moves to the upper position
Service tip: Open the high-capacity feeder front door and check the black rubber bumper attached to the door switch spring. Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly.
1
FRU
Lower limit switch
Lower limit switch cable
High-capacity feeder control board
Action
Check the lower limit switch to make sure it is not closed (normally open). If incorrect, replace the switch. Check the lower limit switch cable for a short between pins 1 and 2. If incorrect, replace the cable.
If correct, replace the high-capacity feeder control board.
Paper from the high-capacity feeder input tray does not reach the pass thru sensor
Service tip: Be sure the paper in tray is within specifications.
FRU
1 Autocompensator assembly
2 Wear strips
Action
Check the autocompensator pick arm rollers for sign of glazing, toner or other buildup. Replace as necessary.
Check the wear strips for glazing or contamination. Replace as required. It is advisable to replace all four wear strips at the same time.
Diagnostic information 2-143
7002-xxx
The elevator tray does not move up or down; the printer recognizes that the option is installed
1
FRU
DC drive motor highcapacity feeder option system board
Action
Be sure the motor cable is correctly installed at J1 on the board.
Check the cables, damaged or loose wires. Disconnect the motor.
Check for a short between each pin and the motor housing. If a problem is found, replace the motor assembly. If no problem is found, measure the resistance between the following pins on the motor cable connector:
Pins 1 (brown) and pin 2 (Yellow)
The resistance measures between approximately 7.5 and 10.5 ohms.
If incorrect, replace the motor assembly. If correct, replace the highcapacity feeder option system board.
The elevator moves in one direction only
1
FRU
DC drive motor assembly high-capacity feeder system board
Action
Check the voltages at J1 on the high-capacity system board. The voltages measure approximately as follows:
Pin Color Voltage
Static (motor not running)
J1-1 Brown 0 V dc
J1-2 Yellow 0 V dc
Motor running forward
J1-1
J1-2
Brown
Yellow
0 V dc
+24 V dc
Motor running in reverse
J1-1 Brown +24 V dc
J1-2 Yellow 0 V dc
If any of the voltages are incorrect, disconnect the motor and measure the resistance between J-1 and J-2. The resistance measures between 7.5 and 10.5 ohms. If incorrect, replace the motor. If correct, replace the system board.
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Paper size switch not selecting paper size that is selected
1
FRU
Paper size switch
High-capacity feeder option control board
Action
Check for continuity between the common pin (J5-1) and the pin of the paper size selected.
Pin
J5-1
J5-2
J5-3
J5-4
J5-5
J5-6
J5-7
Color
Black
Paper size
Common lead
Blue
Green
B5
Executive
Yellow A4
Orange Letter
Red Legal
Brown A5
If any position does not measure continuity when selected, replace the paper size switch assembly. If the switch assembly is operating correctly, replace the high-capacity feeder option control board.
24x.xx Paper Jam Check Tray x displays when tray x is empty; tray x does not display
1
2
FRU
High-capacity feeder option control board
Elevator top optical sensor cable
Elevator top optical sensor
Action
Check the voltages on the board at J4-1(red) and J4-3 (blue). The voltages measure approximately +5 V dc. If incorrect, disconnect J4 from the board and measure the voltages again. If incorrect, replace the high-capacity feeder option control board.
Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly.
Tray x Empty displays; tray does not respond to loading paper; no response from the front door switch
1
2
FRU
High-capacity feeder option control board
Elevator top optical sensor cable
Elevator top optical sensor
Action
Check the voltage on the board at J4-2 (green). The voltage measures approximately +5 V dc. If incorrect, disconnect the cable at
J4 and check the voltage again. If incorrect, replace the high-capacity feeder option control board.
Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly.
Diagnostic information 2-145
7002-xxx
Tray x Paper Low displays when the high-capacity feeder input tray is full or has adequate paper in the tray
1
FRU
Paper low switch
Paper low switch cable
High-capacity feeder option control board
Action
Run the sensor diagnostics for tray x ( x =the number that represents the high-capacity input tray).
If the test fails, check the voltage at J3-1 (gray). The voltage measures approximately +24 V dc. If incorrect, disconnect the paper low switch cable from J3 and measure the voltage again on J3-1. If incorrect, replace the high-capacity feeder option control board. If correct, check the cable for a short between pins 1 and 2 on the cable. If incorrect, replace the cable. If correct, check the switch for a bent or deformed actuator lever or defective switch. If incorrect, replace the switch.
Excessive noise or vibration
FRU
1 DC motor assembly
2 Idler pulley
DC motor assembly
3 Drive pulley
4 Motor drive belt tray drive belt
Action
Make sure all the motor plate mounting screws are tight.
Make sure the idler pulley is not binding on the pulley shaft. Check the pulley for wear. Check the idler pulley shaft on the motor mounting plate for damage or contamination.
Check the drive pulley for wear, binds or damage to the pulley or pulley shaft. Make sure the pulley turns freely on the pulley shaft.
Check the DC motor drive belt for damage. Make sure the belt is tracking correctly on the drive pulley, idler pulley, and motor pulley.
Check the tray drive belt for damage. Make sure the belt is tracking correctly on the lower section of the drive pulley and lead screw pulleys.
Input sensor service check
Service tip: Run the Base Sensor Test. Check the input sensor for proper operation. The display changes from open to closed as the sensor flag is manually moved in and out of the sensor.
1
FRU
Input sensor flag
2 System board
3 Input sensor cable
Action
Check the input sensor flag for damage and proper operation. If a problem is found, repair as necessary.
Check for approximately +5 V dc at J15-10 on the system board. If incorrect, replace the system board.
Check the continuity of the input sensor cable section of the front wiring harness. If incorrect, replace the harness. If correct, replace the input sensor assembly.
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Input tray(s) service check
Optional 250-sheet and 500-sheet trays
Service tip: Try all the other input paper sources to make sure they are properly feeding paper.
For 990 Error Code- Service Tray x , x = displays the number of the tray that has a problem or needs service.
1
FRU
Tray x Option system board or compensator assembly or autoconnect cable
Action
Check the autoconnect cables and connectors for damage. If the cables, connectors, and connections are good, replace the FRUs in the following order:
• Autocompensator assembly option
• Replace the option.
24x.xx Paper Jam displays, paper jammed over the pass thru sensor
(The printer displays the value of x for the paper tray where the error occurs. Example: 241 is a Paper Jam
Tray 1)
1
FRU
Pass thru sensor and flag assembly
2 Power takeoff shaft and spring, bevel gear, feed roll gear, drive roll assembly, wear plate, drive shaft bearings, and skewed backup roller
Action
The tray x option system board did not detect a piece of paper actuating the pass thru sensor. Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu. If the test fails, check the sensor for correct installation and the flag for proper operation. Also check the sensor cable to make sure it is correctly connected to the option system board. If incorrect, replace the tray x option pass thru sensor assembly.
Check these parts for broken or damaged parts, contamination on the drive rollers or wear plate, and wear or damage to the drive shaft bearings. Check the drive roll assembly and skewed backup roller for signs of wear, slick spots, material buildup, and oil or grease on the rollers. Also check for proper operation of the paper aligning assembly. Repair or replace parts as necessary.
Tray x Low displays when tray x is full or has adequate paper in the tray
1
FRU
Paper low sensor assembly
Paper low sensor flag tray x option system board
Action
Run the Tray x Sensor Test and check the sensor for proper operation. If incorrect, check the following:
• Paper low sensor flag for smooth and correct operation.
• Paper low sensor for correct installation on the autocompensator housing.
• Paper low sensor cable for signs of cuts, pinched wiring, or other damage especially at connector J26 on the system board.
If no problem is found, replace the paper low sensor assembly. If this does not correct the problem, replace the option system board.
Diagnostic information 2-147
7002-xxx
Tray x Empty displays when tray x has paper in the tray
FRU
1 Paper out sensor flag
2 Paper out sensor (on option system board)
Action
Check the paper out sensor flag for correct operation and installation.
If correct, replace the option system board. (The paper out sensor is mounted on the system board).
Printer does not recognize Tray x is installed
1
FRU
Autoconnect cables
Tray x system board
Action
Check the autoconnect from the printer or option above tray x . Check for cuts, pinched wiring, or damage to the contacts in the connector.
Check the autoconnect cable(s) for correct installation at the tray x system board. If correct, replace the tray option.
Paper from Tray x does not reach the pass thru sensor
Service tip: Check the media in tray x to make sure it is within specifications. Some types of labels, foil material, and slick papers can cause misfeeds and slippage of the rollers.
1
FRU
Autocompensator assembly
Action
Check the autocompensator pick arm rollers for any sign of glazing, toner or other buildup. Clean or replace as necessary.
Interface card service check
Warning: When replacing any one of the following components:
• Flatbed interconnect card (ICC)
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
Check the interface card for correct installation and for any signs of damage. If the card is damaged, replace the interface card. See
“Interface card assembly removal” on page 4-107 .
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LCD touchscreen contrast control service check—model X642e
Note: If the contrast control only works over part of its travel, replace the left operator panel cover assembly.
See
“Operator panel left cover assembly removal” on page 4-61
.
FRU
1 UICC card #1 to UICC card #3 cable (UICC 8-pin cable)
2 UICC card #1 to UICC card #3 cable (UICC 8-pin cable)
3 Operator panel left cover assembly
Action
Check the cable for correct installation to J1 on UICC card #3 and to
J14 on UICC card #1 (operator panel card).
Check continuity of the UICC 8-pin cable. If correct, go to step 3. If incorrect, replace the cable.
Replace the operator panel left cover assembly. See
“Operator panel left cover assembly removal” on page 4-61
. If this does not fix the problem, replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64 .
LCD touchscreen display service check—models X644e/X646e
LCD touchscreen display complete dark operator panel LED on
CAUTION
When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Note: The LCD touchscreen display can be checked by entering the Diagnostics Menu, selecting HARDWARE
TESTS, and running the Panel Test.
1
FRU
LCD inverter 8-pin cable
Action
Check the inverter 8-pin cable for correct installation to the operator panel card (J13) and to the LCD inverter card (CN1) assemblies. If no problem is found, go to step 2.
2 LCD inverter 8-pin cable Check continuity of the inverter 8-pin cable. If incorrect, replace the cable. If correct, go to step 3.
Diagnostic information 2-149
7002-xxx
FRU
3 LCD inverter card
Action
Check the voltages at CN1-1 and CN1-2.
Operator panel right cover assembly
LCD touchscreen display
LCD Touchscreen display
Connector CN1 (LCD inverter card)
CN1–1 Power
Display dark
+12 V dc
CN1–2 Power
CN1–3 Ground
CN1–4 Ground
CN1–5 Lamp Off
+12 V dc
0 V dc
0 V dc
0 V dc
CN1–6 Vbright adj
CN1–7 Ground
0 V dc
0 V dc
CN1–8 Ground 0 V dc
Note: All voltages are approximate values.
*approximate, depending on brightness.
Display lit
+12 V dc
+12 V dc
0 V dc
0 V dc
+4 V dc
+4 V dc*
0 V dc
0 V dc
If the voltages at CN1-1 and CN-2 are incorrect, replace the LCD inverter card. See
“LCD inverter card assembly removal” on page 4-108 .
If this does not fix the problem, replace the operator panel right side cover assembly. See
“Operator panel right cover assembly removal” on page 4-64
. If the voltages at CN1-1 and CN1-2 are correct, replace the inverter card. If this does not fix the problem
replace the touchscreen display. See “LCD touchscreen removal— models X644e and X646e” on page 4-67
.
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LCD touchscreen backlight—models X644e/X646e
Unable to change LCD touchscreen backlight.
1
FRU
Inverter card 8-pin cable
Action
Check to make sure the cable is installed correctly to the inverter card and to the operator panel card.
2 Inverter card 8-pin cable Check continuity of the 8-pin inverter card cable. If correct, go to step
3. If incorrect, replace the cable.
3
4
Inverter card
Inverter card assembly
Operator panel right cover assembly
Check the voltages on CN1-1 and CN1-2. They should measure approximately +12 V dc.
Inverter card
Connector Cn1 (to operator panel card)
Pin number Voltage
CN1—Pin 1
CN1—Pin 2
CN1—Pin 3
+12 V dc
+125 V dc
0 V dc
CN1—Pin 4
CN1—Pin 5
CN1—Pin 6
CN1—Pin 7
CN1—Pin 8
0 V dc
0 V dc (screen light Z) +4–5 V dc (screen dark)
0–+5 V dc BRIGHTNESS ADJUST
0 V dc
0 V dc
If incorrect, replace the operator panel card assembly. If correct, go to step 4.
Enter the following Menus, Settings, General Settings, and Screen
Brightness on the touchscreen display.
• Enter 22 on the touchscreen display, and Submit the new setting. Measure the voltage at CN1-5. The voltage should measure approximately 0 to +1.5 V dc.
• Enter 50 on the touchscreen display, and Submit . Measure the voltage at CN1-5. The voltage should measure approximately
+2.7 V dc.
• Enter 100 on the touchscreen display, and Submit . Measure the voltage at CN1-5. The voltage should measure approximately
+5.0 V dc.
If the voltages do not change when going from 22 to 100 on the display, replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64 .
If this does not fix the problem, replace the LCD inverter card assembly. See
“LCD inverter card assembly removal” on page 4-108 .
Diagnostic information 2-151
7002-xxx
LCD touchscreen display lights up, icons displayed, but it does not work when touched.
1
2
3
4
FRU
LCD touchscreen display/
4-pin cable
LCD touchscreen display
Operator panel right cover assembly
Inverter card
Inverter card assembly
Operator panel right cover assembly
Action
Check the 4-pin display to operator panel card cable for correct installation to J3 on the operator panel card.
Note: This cable is a short ribbon cable that can easily become disconnected from J3 on the operator panel card.
If the cable is properly installed, go to step 2.
If the cable is connected properly to J3, replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64
. If this does not fix the problem, replace the
LCD touchscreen display assembly. See
“LCD touchscreen removal—models X644e and X646e” on page 4-67
.
Check the voltages on CN1-1 and CN1-2. They should measure approximately +12 V dc.
Inverter card
Connector Cn1 (to operator panel card)
Pin number Voltage
CN1—Pin 1
CN1—Pin 2
CN1—Pin 3
CN1—Pin 4
CN1—Pin 5
CN1—Pin 6
CN1—Pin 7
CN1—Pin 8
+12 V dc
+125 V dc
0 V dc
0 V dc
0 V dc (screen light Z) +4–5 V dc (screen dark)
0–+5 V dc BRIGHTNESS ADJUST
0 V dc
0 V dc
If incorrect, replace the operator panel card assembly. If correct, go to step 4.
Enter the following Menus, Settings, General Settings, and Screen
Brightness on the touchscreen display.
• Enter 22 on the touchscreen display, and Submit the new setting. Measure the voltage at CN1-5. The voltage should measure approximately 0 to +1.5 V dc.
• Enter 50 on the touchscreen display, and Submit . Measure the voltage at CN1-5. The voltage should measure approximately
+2.7 V dc.
• Enter 100 on the touchscreen display, and Submit . Measure the voltage at CN1-5. The voltage should measure approximately
+5.0 V dc.
If the voltages do not change when going from 22 to 100 on the display, replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64 .
If this does not fix the problem, replace the LCD inverter card assembly. See
“LCD inverter card assembly removal” on page 4-108 .
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Main drive service check
Service tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or system board.
Warning: Whenever the gearbox assembly is removed from the machine it must be handled very carefully.
Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage. It is also very important not to let any dirt, paper, staples, or other material come intact with the grease in the gearbox assembly.
1
FRU
Main drive assembly
(excessive noise or vibration)
2 Main drive motor assembly
(excessive noise, gears ratcheting and so on)
3 Main drive motor cable
4 Motor gear does not turn, no 936 error code or
201.xx Paper Jam
user message displays.
Action
Remove the controller board and run a Diagnostic Print Test in the continuous mode. Check the main drive assembly for any excessive noise or vibration. Determine if the noise is in the main drive, toner cartridge, fuser, or main drive gearbox. Look for any loose or worn parts in the developer drive assembly, main drive gearbox, or fuser.
Repair as necessary.
A service error code 936 - Transport Motor may be displayed. Check the voltage at J20-6 on the system board. It measures approximately
+5 V dc when the motor is not running and goes to 0 V dc when the motor is running. If incorrect, replace the system board. If this does not fix the problem, replace the main drive motor.
Check the continuity of the main drive motor cable. If incorrect, replace the cable.
Check the voltages at J20 on the system board.
Pin
J20-11
J20-8
J20-7
J20-6
J20-5
J20-4
J20-1
Static
+5 V dc
+5 V dc
+5 V dc
+5 V dc
+5 V dc
+5 V dc
Voltage
When main drive motor is running
+24 V dc
0 V dc
0 V dc
+2.5 V dc
0 V dc
+5 V dc
0 V dc
If the voltage is incorrect, replace the FRUs in the following order:
• Main drive motor assembly
• System board
Diagnostic information 2-153
7002-xxx
Operator panel Help and Home buttons service check—model X642e
Note: Run the Button Test from the Diagnostics Menu to determine if the buttons are operating properly. See
FRU
1 UICC card #1 to UICC card #2 cable
(UICC 4-pin cable)
2 UICC card #1 to UICC card #2 cable
(UICC 4-pin cable)
3 Bezel assembly
Action
Check the UICC 4-pin cable for correct installation to J15 on UICC card #1 and to J1 on UICC card #2. If installed correctly, go to step 2.
Check continuity of the UICC 4-pin cable. If correct, go to step 3. If incorrect, replace the cable.
Replace the bezel assembly which has UICC card #2 attached. If this does not fix the problem, replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64
.
Operator panel Menu button service check—model X642e
Note: Run the Button Test from the Diagnostics Menu and check the button for proper operation. See
FRU
1 UICC card # 1 to UICC card #3 cable
(UICC 8-pin cable)
2 UICC card #1 to UICC card
#3 cable
(UICC 8-pin cable)
3 Operator panel left cover assembly
Action
Check the cable for correct installation to J1 on UICC card #3 and to
J14 on UICC card # 1 (operator panel card). If installed correctly, go to step 2.
Check continuity of the UICC 8-pin cable. If correct, go to step 3. If incorrect, replace the cable.
Replace the operator panel left cover assembly. See
“Operator panel left cover assembly removal” on page 4-61
. If this does not fix the problem replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64 .
Operator panel right cover assembly service check
Operator panel LED off.
FRU
1 UICC 18-pin operator panel to scanner control card cable
2 UICC 18-pin operator panel to scanner control card cable
Scanner control card
3 Scanner control card
Action
Check to make sure the cable is correctly connected to J10 on the operator panel card and to J15 on the scanner control card. If the cable is correctly connected, go to step 2.
Check the cable for any signs of damaged or bent pins. If incorrect, replace the cable. If correct, go to step 3.
Measure the voltage at J15-17 and J15-18. The voltage should measure approximately +24 V dc. If incorrect, replace the scanner control card. See
“Scanner control card removal” on page 4-48
. If correct, replace the operator panel right cover assembly. See
“Operator panel right cover assembly removal” on page 4-64 .
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Options service check
Service tip: When you have a problem with any of the options installed in the options slots on the system board, switch the non operating option to one of the other option slots to isolate the failure.
Flash memory option(s)
Run a copy of the test page and check to see if the option you are checking is listed. The printer does not recognize the option being installed if the option is not listed. Make sure the memory card is installed correctly and is not broken or damaged. If the memory card is correctly installed and not broken or damaged then run the
. If the test fails, replace the Flash card. If the problem continues, replace the controller board.
DRAM memory option(s)
This service check is the same as the flash memory option service check with the following exception:
Run the
“DRAM Test” on page 3-9 from the menu if the SDRAM Memory card is correctly installed and not
broken or damaged. If the test fails, replace the SDRAM card. If the problem continues, replace the controller board.
Hard disk option
Service tip: Model X646e supports one hard disk option. Make sure only one hard disk option is installed.
from the Device Test on the Diagnostics menu when a problem is suspected either with the hard disk system board or with the hard disk.
Note: The Quick Disk Test is a non-destructive test and indicates Pass or Fail. If the test fails, replace the hard disk. If a problem still exists, replace the hard disk board.
The
“Disk Test/Clean” on page 3-16 is used to help restore the disk if the disk contains bad data and is
unusable. This test is divided into a cleaning and a verifying or testing section.
Warning: This can be a very lengthy test depending on the disk size. This test leaves the hard disk unformatted. The servicer or user must reformat the disk using the Format Disk Menu operation.
This is a destructive type of test. All the data on the disk is destroyed and should not be performed on a known good disk.
Error Code 976.xx - Network Card x (x=Network card 1, 2, or 3)
A 976 error code indicates an unrecoverable software error in network card x . Verify that network card x is correctly installed in the socket on the interconnect card and is properly grounded. If you find no problem, contact your next level of support before replacing the network card.
Error Code 977.xx - Network Card x
A 977 error displays when the RIP software detects that a network card is installed in slot x on the interconnect card but cannot establish communications with the network card.
Diagnostic information 2-155
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Output bin sensor standard tray service check
Service tip: If the output bin standard tray fills up and the bin full sensor fails to post the Remove Paper Standard
Bin message:
1.
Enter the Diagnostics Mode.
2.
Select Output Bin Tests .
3.
Select Sensor Tests .
4.
Select Standard Bin .
5.
Check the sensor and flag for proper operation.
If you find no problem with the sensor and flag, continue with the service check.
Service tip: Be sure the flag is correctly installed. The output bin sensor is a normally closed sensor with the sensor flag down. Therefore, unless the flag is in the up position or out of the sensor slot, a Remove Paper
Standard Bin message does not display.
FRU
1 System board
Printer fails to display
Remove Paper Standard
Bin
message.
Output Bin Sensor Test fails.
2 Output bin sensor flag
Action
Check the voltage at J6-1. It measures +5 V dc when the flag is in the sensor, and 0 V dc when the flag is out of the sensor. If the voltage does not change, replace the sensor cable assembly. If this does not fix the problem, replace the system board.
Make sure the correct flag is installed. Check the flag for damage or improper operation. If incorrect, replace the flag.
Note: A broken or improper operating sensor flag causes a
Remove
Paper Standard Bin
message to display before POST completes and cannot be cleared.
Paper feed service check—printer
If you have a 936 Transport Motor Error go to
“Main drive assembly removal” on page 4-113 .
1
FRU
Alignment assembly
2 Inner deflector
Action
Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight. Check the alignment assembly for worn rollers, contaminated rollers, or binds.
Replace the alignment assembly if any problem is found.
Check the inner paper deflector for correct installation. If the deflector is bowed or not fitting correctly, replace the deflector.
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Autocompensator fails to feed paper. Failures occur randomly throughout the stack of paper
FRU
1 Pass thru sensor
2 Autocompensator assembly
3 Wear strips in tray x problem is found.
Action
Check the pass thru sensor for correct installation and operation.
The autocompensator pick roll shaft assembly is not providing enough torque if the pick rollers are not picking the paper correctly.
Replace the autocompensator assembly.
Check the wear strips for excessive wear, scratches, or rough spots.
Replace the wear strips if a problem is found.
Paper feed failures occur only near the top of the stack of paper
The most common cause of this problem is paper curl. Remove the paper from tray x and check for the natural curvature in the paper. Reinstall the paper in the correct manner. If the problem persists, it may be necessary to reduce the stack height. Replace both pick rolls if the paper appears to be flat in the tray but there is still a problem.
Failures occur mainly near the bottom of the stack of paper
The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly contact the paper. Also the autocompensator motor may be failing. If this problem continues replace the autocompensator assembly.
Double feeding paper
Note: If double feeding paper occurs mostly from the bottom of the stack, check for missing or damaged restraint pads in the tray.
1
FRU
Paper
2 Autocompensator
Action
Paper is usually the primary cause of a double feeding paper problem. Flex the paper before placing the paper in the tray. Edgewelded paper is the most common cause of double feeding. Loading the paper in the tray in different locations and directions and using rough paper and short grain paper also causes double feeding.
Make sure the counterbalance spring is not missing, loose, or broken at the top of the autocompensator arm assembly. If you find a problem, replace the autocompensator assembly.
Paper fails to feed from the multipurpose tray
The pick roll should make one complete revolution and stop with the flat side down. If the pick roll turns but does not pick paper, check the roll for signs of wear, oil or grease on the surface of the pick roll or slick spots. If you find a problem, replace the pick roll assembly. Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications.
Diagnostic information 2-157
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Paper size sensing service check
Before proceeding, check for the correct paper size loaded in the tray and that the tray has been set to accept the size paper loaded in the tray.
SW2
SW1
SW0
CN1
1
Paper size sensing switch chart
ITC
CN1 pin
1
2
3
4
Signal
PSIZE2
Ground
PSIZE1
PSIZE3
ITC switch
SW1
Ground
SW0
SW2
Paper tray size selection (X is activated)
A4 Exec B5 Letter Legal
X X X
X
X X
X
X
A5
X
System board
J34 pin
1
2
3
4
Tray 1 not recognized as being installed; unable to clear Tray 1 Missing message
1
FRU
Tray 1
Action
Check Tray 1 for damaged or broken autosize fingers. Check for anything that would prevent the autosize fingers from activating the paper activate springs and ITC switches.
LGL
A4
LTR
EXEC
A5
S
W
2
W
1
S
S
W
0
2 Integrated card/ autocompensator cable
3 System board
If a problem is found, repair or replace the tray assembly. If no problem is found, go to step 2.
Check for correct installation of the cable at J26 on the system board.
If installed correctly, go to step 3. If incorrectly installed, install and recheck the printer.
Check the continuity between J26-2 on the system board and ground. It should measure approximately 0 ohms.
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The printer does not recognize the paper size selected
FRU
1 Back restraint
Side restraint
Snap-in plate
Autosize slider
Autosize finger
2 Switch activate spring
Paper size sending board
3 System board
ITC cable
4
5
System board
Autocomp cable
Action
Check all the paper size parts for damage or broken parts. make sure the parts operate correctly. If a problem is found, repair as necessary. If no problem is found, go to step 2.
Make sure the switch activate spring is not bent or broken. Replace the spring if damaged. If the spring is not damaged, go to step 3.
6
7
8
4
5
1
2
3
9
10
Set the tray for the paper size that is not recognized and install the tray in the printer. Select the paper size and corresponding paper switch from table, below.
Pin
J26
Signal
PSIZE2
Ground
PSIZE1
PSIZE3
+3.3
Static tray out
(V dc)
Static with paper tray in and set to: (V dc)
Letter
+3.3 0
0 0
Legal
0
0
A4
+3.3
0
Exec
+3.3
0
B5
0
0
A5
+3.3
0
+3.3
+3.3
+3.3
0
+3.3
+3.3
N/A
0
+3.3
0
0
0
+3.3
+3.3
0
+3.3
+3.3
N/A
N/A
+3.3
N/A
N/A
+3.3
+3.3
+3.3
+3.3
If the voltage on J26 does not change, go to step 4. If the voltage changes, recheck the printer. If
Tray 1Missing
is still displayed, replace the system board assembly.
Ground the appropriate pin on connector J26 on the system board.
Tray 1 Missing
should not be displayed. If it is not displayed, go to step 5. If it still displays, replace the system board assembly.
Check continuity of the autocomp cable. If correct, replace the ITC assembly. If incorrect, replace the autocomp cable.
Parallel port service check
Run the
“Parallel Wrap test” on page 3-10 .
Note: The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug (P/N
1319128) and invoking the Parallel Diagnostic Test. This test helps isolate the printer from the parallel cable and host. The test provides failure information on the display for approximately three seconds. If the test indicates that a problem is detected, replace the controller board.
Diagnostic information 2-159
7002-xxx
Print quality service check
Service tip: Before troubleshooting any print quality problems do the following:
•
Install another print cartridge if available before proceeding with the service checks.
•
Use Tray 1 to test for print quality of the printer.
•
Replace the charge roll if it is damaged or contaminated.
•
Replace the transfer roll if it is damaged or contaminated.
•
Make sure the fuser assembly is installed correctly.
•
Verify proper paper type, texture, and weight settings for the media being used.
•
Test the printer using plain paper (20 lb).
Select the following menu settings as indicated. Be sure and note the original settings so you can return the printer to the original customer printer setup.
• Print Resolution: Set to 300 dpi (print quality problems should be checked at different resolution settings).
• Print Darkness: Set to NORMAL.
• Toner Saver: Set to OFF.
• PQET: Set to OFF.
• Fuser Temperature: Set to NORMAL.
• Test the printer using plain paper (20 lb).
An incorrect printer driver for the installed software can cause problems. Incorrect characters could print, and the copy may not fit the page correctly.
Measure all voltages from the connector to printer ground. All voltages measured during the print cycle are measured with the controller board removed while running the print test.
Print quality—all black page
Service tip: An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum.
1
FRU
High voltage contacts
2 Charge roll conductive bushing
3 HVPS
Action
Check the high voltage contacts on the right side frame to ensure they fit securely and are not pitted, contaminated, or damaged. If incorrect, replace the contact with one from the HV contact kit.
Screws and plastic blocks are included to attach the contacts to the right side frame in the HV contact kit.
Make sure the charge roll bushing is correctly installed in the right charge roll arm.
Check the voltages on J15-1 thru J15-8. If incorrect, replace the system board.
4 HVPS cable
(part of front harness cable)
System board
Check the continuity of the HVPS cable. If incorrect, replace the cable assembly. If correct, replace the system board.
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Print quality—blank page
1
FRU
Print cartridge
2
3
4 Front cable harness HVPS section
5
High voltage contact
HVPS
Printhead assembly
Action
Check the print cartridge for damage, especially the PC drum contact on the cartridge.
Check the PC drum contact on the right side frame for damage, PC drum contact wear or contamination. If the contact is bent or damaged, replace the contact.
Note: Inspect the HVPS PC drum contact on the board for damage or contamination.
Check the fuse on the HVPS. If open, replace the HVPS. Check the voltages at J22 on the system board. Measure the following voltages from connector J22 to printer ground:
• Printer Idle
J15-5 measures +24 V dc
• Printer Printing
J15-5 measures +24 V dc
If the voltages at J10-5 are incorrect, replace the system board.
Check the front cable harness at J15 on the system board and at
CN1 on the HVPS to make sure the harness is connected properly. If connected properly, check the continuity of the cable harness. If there is no continuity, replace the front cable harness.
Generally a 93 x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom.
The printhead used in the printer does not have a mechanical shutter as previous laser printers. The printer is interlocked through the front top cover interlock switch.
Print quality—random marks
Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor, charge roll, or transfer roll.
1
Symptom
Random marks
Action
Check the print cartridge for loose or foreign material that might be on the photoconductor. Check the transfer roll and charge roll for any pieces of material that are stuck to the rolls.
Print quality—blurred or fuzzy print
Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly, alignment assembly, any feed roller, or in the transfer roll bearings or transfer roll. Check the gearbox assembly for correct operation.
Check the transfer roll for binds or a contaminated shaft or bearings.
Blurred print can also be caused by incorrect feeding from one of the input paper sources, paper trays, duplex option, or envelope feeder.
Check the high voltage contacts to ensure they are not bent, corroded, or damaged. Replace as necessary.
Diagnostic information 2-161
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Print quality—background
Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting.
Some slick or coated papers may also cause background problems. Some problems occur with printers that run a large amount of graphics in a humid environment. The customer may try to improve the print quality by increasing the transfer setting.
Check the charge roll to make sure it is not at the end of life.
1
FRU
Printhead
2 Transfer roll assembly
3 High voltage contacts
4 System board HVPS connector
Action
The printhead on this printer cannot be cleaned. Try another printhead if all other attempts fail to correct a background problem.
Check the high voltage contact from the HVPS to the transfer roll.
Check the transfer arm assembly right side bearing for contamination, pitting, or a loose cable to the bearing. If any problems are found, replace the defective part. Check the transfer roll shaft for contamination, wear, or pitting on the ends of the shaft that go into the bearings. If a problem is found, clean the ends of the shaft or replace the transfer roll assembly.
Check the high voltage contacts on the right side frame to ensure they are clean and not bent, deformed, or pitted. If incorrect, replace the contact.
Check the following voltages at J15 on the system board. Measure the voltages from J15 to printer ground.
Pin J15
Printer idle
J15-1
Voltage (approximate)
0 V dc
J15-2
J15-4
+4 V dc
0 V dc
Printer printing
J15-1 0 V dc to +5 V dc
J15-2 0 V dc to +4 V dc
J15-4 0 V dc to +1.9 V dc
If J15-1 voltage is incorrect, check the continuity of the front harness cable (J15-1 line). If there is no continuity, replace the harness cable.
If there is continuity, replace the HVPS. If this does not correct the problem, replace the system board.
If J15-2 voltage is incorrect or if the voltage remains at 0 V dc, check the continuity of the front harness cable (J15-2 line). If there is no continuity, replace the harness cable. If there is continuity, replace the HVPS. If this does not correct the problem, replace the system board.
If J15-4 voltage is incorrect, check the front harness cable (J15-3 line). If there is not continuity, replace the harness cable. If correct, replace the system board. If this does not correct the problem, replace the HVPS.
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Print quality—banding
Service tip: Banding is difficult to detect, except on a page with a uniform gray or a large amount of graphics printed on the page. Banding is primarily due to a variation in the speed of the paper as it feeds through the printer, especially in the development and transfer process. Inspect the alignment assembly, main drive assembly, and all other paper feed components for signs of wear, dirt, binds, or damage, especially the drive gears. Banding appears as light or dark horizontal lines on a uniformly gray page.
Banding can also be caused by a defective charge roll brush contact or HVPS. Check the charge roll contact for damage and for proper connection to the HVPS and print cartridge.
Print quality—black bands on outer edges of the page
This print quality problem appears as vertical black bands on one or both sides of the copy and can be wide, narrow, light, or dark.
1
2
3
FRU
Charge roll counterbalance springs
Charge roll assembly
Charge roll link arm
HVPS
Action
If the problem is just on one side of the page, check the charge roll counterbalance spring on that side. You can check to see if enough force is being applied to the charge roll by applying slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample. See if the problem changes or goes away. If this fixes or changes the problem, then check the springs and charge roll link arm assemblies for binds or defective parts. Replace as necessary.
Check the charge roll for toner buildup or other contamination on the outer edges that correspond to the bands on the page. Check the charge links and arms for proper operation, binds or incorrectly mounted counterbalance springs. Repair or replace as necessary.
Check the following voltages at J15-8 on the system board:
• Printer Idle
J15-8 measures 0 V dc
• Printer Printing Test Page
J15-8 voltage changes from 0 V dc to +4 V dc
If the voltage does not vary, check the continuity of line J15-8 in the front cable harness. If there is no continuity, replace the cable harness. If there is continuity, replace the HVPS. If this does not correct the problem, replace the system board.
Turn the printer off, and check the resistance between J15-7 and printer ground. The resistance measures approximately 0 ohms. If incorrect, make sure the system board is mounted correctly and securely grounded. If correct, replace the system board.
Print quality—residual image
Service tip: Install a new print cartridge if available before doing this service check. Residual image can be caused by the photoconductor, cleaning blade, and other parts inside the print cartridge.
1
FRU
Hot roll fuser assembly
Action
Check the fuser assembly for toner contamination. The hot roll especially might cause toner to be retained and deposited on the page.
Diagnostic information 2-163
7002-xxx
Print quality—light print
Service tip: Check the toner saver and print darkness settings first if the print is light.
1
FRU
Transfer roll
2 Right side transfer roll arm assembly
HVPS
3
4
Printhead cable
Printhead
Action
Check the right end of the transfer roll shaft for signs of wear or contamination. If incorrect, replace the transfer roll.
Check the right side transfer roll arm assembly bearing for wear or contamination. Also make sure the transfer cable is firmly attached to the bearing. If incorrect, replace the right side transfer arm assembly.
Check the connection of the transfer roll assembly cable to the transformer on the HVPS board. Check the continuity of the cable from the bearing to the spade terminal on the cable. If incorrect, replace the right side transfer arm assembly. If correct, replace the
HVPS.
If the printer is not already at 1200 dpi, change the Print Resolution setting to 1200 dpi and see if the darkness level changes:
1. In Ready state, press Menu .
2. Select Settings , and press Select .
3. Select Quality Menu , and press Select .
4. Select Print Resolution , and press Select .
5. Select 1200 dpi .
6. Press Back until Ready appears.
7. Print a test page (if you want to print an internal test page, Print
Fonts is the only internal 1200 dpi document). If printing in 1200 dpi is correct and not light, but other printing at other dpi settings print light, there may be damage to the printhead cables.
Check the printhead cables for any signs of damage. Check the area of the wire tie on the printhead laser cable for damage. If damaged, replace the cable. If not damaged, go to step 3
A contaminated printhead may be the cause of light print. If no other cause is found, install a new printhead. See
“Printhead removal” on page 4-127 .
Print quality—toner on backside of printed page
Service tip: This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper.
1
FRU
Hot roll fuser assembly
2 Transfer roll transfer plate assembly
Action
Toner is being carried out on the backside of the media. This problem is generally caused by a toner buildup on the fuser hot roll or backup roll. Check the fuser hot roll and backup roll for any noticeable buildup of toner. Repair as necessary.
Check the transfer roll for toner buildup or loose toner around the area of the transfer plate assembly. Clean the area and run another copy. If the problem continues, replace the FRUs in the following order:
• HVPS
• System board
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Printhead service check
CAUTION
The printhead is not a serviceable FRU. Do not disassemble the printhead.
The printhead assembly does not contain any service replaceable parts or components. If service error code
930.xx displays, the wrong printhead is installed in the printer. See
.
Note: A 201.xx paper jam may also indicate a failing printhead. The paper may have jammed prior to or at the input sensor. Print the event log and see if 201 or 931 errors are logged.
1
Service error code
Error code 931.xx
No first HYSNC Signal
Error Code 932
Lost HYSNC
2 Error Code 934.xx
Mirror motor lost lock Error
Code 935
Mirror motor unable to reach operating speed
Explanation
These errors usually indicate a failure in the HYSNC signal to the printhead. Check the continuity of the cables connected to J2 and J4 on the system board. If incorrect, replace the defective cable. The voltage at J4-1 measures approximately +5 V dc. If incorrect, replace the system board. The voltage at J2-7 measures approximately
+24 V dc. If incorrect, replace the system board. If correct, replace
the printhead assembly. See “Printhead removal” on page 4-127
.
These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the system board cable or system board assembly. The voltage at J5-2 measures approximately +24 V dc. If incorrect, replace the system board. If correct, replace the FRUs in the following order:
• System board. See
“System board and inner shield removal— model X642e” on page 4-130
or
“System board and inner shield removal —models X644e/X646e” on page 4-131
.
• Printhead assembly See “Printhead removal” on page 4-127
.
Scan quality service check
Determine if the problem is in the scanner assembly or in the base printer. Enter the Diagnostic Menu and select
Print Quality Test Pages. Make sure the printer is set to specifications before using the test pages on the scanner. Check the test pages to help determine if the problem is in the base printer or the scanner. If the problem is in the scanner, ADF, or flatbed use the test pages to help isolate the problem in the appropriate scanner assembly and continue with this service check. If the problem is in the base printer, see
“Print quality service check” on page 2-160 .
Vertical streaks or lines on image
Note: Perform the
“Cleaning the scanner glass, cushions, and strips” on page 6-2
before proceeding with this service check.
Note: Vertical streaks can be caused by debris in the optical path of the CCD module(s). Check for any signs of pieces of media or other debris in or around the ADF CCD, flatbed contact glass, or flatbed CCD.
1
FRU
Models X644e, X646e
2 Model X642e
Action
If you do not have one of these models, to step 2.
If the vertical streaks only occur with the ADF scanner assembly, go to step 3. If the streaks are in the flatbed scanner assembly, go to step 7.
Go to step 7.
Diagnostic information 2-165
7002-xxx
FRU
3 ADF CCD module glass
(models X644e/X646e)
4 Lower exit guide assembly
(models X644e/X646e)
Action
Check for any signs of contamination on the ADF CCD module glass.
Use a clean, soft lint-free cloth with isopropyl alcohol (if available) to clean the glass if any contamination is found.
Note: The ADF module glass can be accessed by removing the flatbed white cushion from the ADF and lower the exit guide assembly.
If the problem persists go to step 4.
Check the lower exit guide backside assembly for any signs of damage to the back ADF white cushion or hardware.
Models X644e/X646e
5 ADF frontside bracket assembly strip
6 ADF CCD module assembly
If the back ADF white cushion cannot be cleaned properly, is damaged, or is missing, replace the lower exit guide assembly. See
“Lower exit guide assembly removal” on page 4-47 .
If no problem is found with the lower exit guide assembly, go to step 5.
Check the ADF frontside bracket assembly for any signs of damage to the front flatbed white strip. If damaged, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
If no problem is found, check the front flatbed white strip for any signs of dirt, debris, or contamination. If any problem is found, clean the strip with a clean, soft, lint-free cloth with isopropyl alcohol (if available).
If this does not fix the problem, or no problem is found, go to step 6.
Replace the ADF CCD module assembly. See
“ADF CCD module assembly removal (models X644e/X646e)” on page 4-14
.
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FRU
7 Flatbed contact glass
(models X642e/X644e/
X646e)
Action
Check for any signs of contamination on the flatbed contact glass.
8 Flatbed glass holder assembly
(models X642e/X644e/
X646e)
9 ADF frontside bracket assembly strip
10 Flatbed CCD module
(models X642e/X644e/
X646e)
Use a clean, soft, lint-free cloth with isopropyl alcohol (if available) to clean the glass of any contamination.
If the problem still persists, go to step 8.
Note: It is recommended that you remove the glass and clean both sides.
Check for any signs of contamination of the flatbed glass holder. Use a clean, soft, lint-free cloth with isopropyl alcohol (if available) to clean the glass if any contamination is found on the glass.
If after cleaning, the problem persists, go to step 9.
Check the ADF frontside bracket assembly for any signs of damage to the front flatbed white strip. If damaged, replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
If no problem is found, check the front flatbed white strip for any signs of dirt, debris, or contamination. If any problem is found, clean the strip with a clean, soft, lint-free cloth with isopropyl alcohol.
If this does not fix the problem, or no problem is found, go to step 10.
Replace the flatbed CCD module. See
“Flatbed CCD module assembly removal” on page 4-28 .
Diagnostic information 2-167
7002-xxx
All black or blank image
This symptom may be caused by insufficient illumination from the lamps in the CCD, a defective CCD, or an electrical problem.
FRU
1 Determine which portion of the scanner has the problem.
2 ADF CCD module to the interconnect board cable
(models X644e/X646e)
3 ADF CCD module to the interconnect board cable
(models X644e/X646e)
4 Flatbed interconnect board
(CN5) to scanner control card (J28) cable.
(models X644e/X646e)
5 ADF CCD module
7
(models X644e/X646e)
Flatbed interconnect card
Scanner control card
6 Flatbed CCD module to flatbed interconnect board
(J2) cable
Flatbed CCD module
Action
If the problem is with the ADF portion of the scanner assembly, go to step 2. If the problem is with the flatbed scanner assembly, go to step 6.
Check the 36-pin flatbed interconnect board to ADF CCD module cable to make sure it is connected properly to both the CCD module and the flatbed interconnect board.
If it is not connected properly, reconnect and recheck the MFP. If the problem is still present, go to step 3.
Check the cable to make sure it is properly connected to both the flatbed interconnect card and to the scanner control card. If it is properly installed, check the cable for any signs of damage, bent pins, or so forth. If any damage is found, replace the complete ADF scanner assembly. See
“ADF complete assembly removal” on page 4-15
.
If no problem is found, go to step 4.
Check the cable to make sure it is properly connected to both the flatbed interconnect card and to the scanner control card. If it is properly installed, check the cable for any signs of damage, bent pins, or so forth. If any damage is found, replace the complete ADF scanner assembly. See
“ADF complete assembly removal” on page 4-15
.
If no problem is found, go to step 5.
Replace the ADF CCD module. See
“ADF CCD module assembly removal (models X644e/X646e)” on page 4-14 . If this does not fix
the problem, replace the following FRUs in the order listed:
• Flatbed interconnect card
• Scanner control card
Check the cable to make sure it is properly connected to both the flatbed CCD module and to the flatbed interconnect card. If properly installed, check the cable for any signs of damage, ben pins, and so forth. If any damage is found, replace the cable.
If no problem, is found, go to step 7.
Replace the flatbed CCD module. See
“Flatbed CCD module assembly removal” on page 4-28 . If does not fix the problem,
replace the scanner control card. See
“Scanner control card removal” on page 4-48
.
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Line compression
Note: This problem is usually caused by “shocks” of media entering or exiting any roller pairs.
1
FRU
Media
2 Lower exit guide assembly
3
4
5
ADF assembly
Pick mechanism
Separator arm
Flatbed CCD module
Action
Measure the distance from the leading or training edge of the media to the compression.
• If the distance is approximately 53mm from the leading edge, go to step 2.
• If the distance is approximately 57mm from the leading edge of the media, go to step 3.
• If the distance is approximately 137mm from the training edge of the media, go to step 4.
This can be caused by the impact of the media entering the second scan area. Replace the lower exit guide assembly. See
“Lower exit guide assembly removal” on page 4-47
.
This can be caused by the shock of the media being released from the first scan roller. Replace the complete ADF assembly. See
“ADF complete assembly removal” on page 4-15 .
This can be caused by the shock of paper release from the feed/ separator roller. Replace the following FRUs in the order listed:
• Pick mechanism. See
“ADF pick assembly removal” on page 4-7
.
• Separator assembly. See “Separator assembly torque limiter removal” on page 4-52
.
This problem can be caused by flatbed motor vibration and will usually appear at the left or right edges of a scan.
Replace the following FRUs in the order shown:
• Flatbed CCD module
• Flatbed scan motor
Wavy lines
Wavy lines seen only on flatbed text or mixed mode up to 300 dpi scans.
1
FRU
Flatbed CCD module assembly
Action
• Replace the flatbed CCD module assembly. See “Flatbed CCD module assembly removal” on page 4-28
. If the problems
continue, replace the flatbed scan motor. See “Flatbed scan motor assembly removal” on page 4-41
.
Diagnostic information 2-169
7002-xxx
Signature button assembly service check
Note: If you are unable to clear a
32.xx-Unsupported Cartridge
User Error message, be sure a Lexmark T64x print cartridge is correctly installed in the printer. The cartridge is easily identified by the contact board on the right side rear of the cartridge. Install another print cartridge before attempting to troubleshoot the printer. Make sure the signature button cable is properly connected to J14 on the system board. Check the print cartridge for damage or improper installation of the chip. Also, be sure there is proper contact between the chip on the cartridge and the signature button contact assembly.
Service tip: An intermittent
32.xx-Unsupported Cartridge
User Error message can be caused by poor contact between the signature button cartridge contacts in the upper front cover and the chip. Also check for proper seating of the signature button cartridge cable to the system board.
1
FRU
Signature button contact assembly
System board
Action
Check the voltage on the signature button cartridge contact. The voltage measures approximately +3.8 V dc when not writing data to the system board. If data is being written, the voltage measures approximately 0 V dc. If incorrect, disconnect the cable from J19 on the system board, and check the voltage on J19-1. The voltage measures approximately +5 V dc.
• If incorrect, replace the system board.
• If correct, replace the signature button cartridge contact assembly.
System board service check
Warning: When replacing any one of the following components:
• Flatbed interconnect card (ICC)
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component, and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
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Toner sensor service check
Service tip: Check the print darkness menu setting before checking the toner sensor.
This service check is intended to be used when a 929.xx Service Error displays.
1
FRU
Developer drive assembly
2 Front harness cable
3 Toner sensor
Action
Incorrect operation of the developer drive assembly can cause the printer to display a 929.xx error code (Toner Sensor). Check the developer drive assembly for correct installation or, any sign of worn, loose, or broken parts.
Check the toner sensor portion of the front harness cable to make sure it is properly seated into the toner sensor. If correct at both the sensor and system board (J15), check the continuity of the cable. If incorrect, replace the cable.
The toner sensor cable is part of the front harness and part of connector J15 on the system board. Check the voltage at J15-11. It reads approximately +5 V dc. If incorrect, replace the system board.
If correct, check the voltage at J15-12. It reads approximately
+5 V dc with the system board removed from the printer. If incorrect, replace the system board. If correct, replace the toner sensor assembly. A bad ground connection between J15-13 on the system board and pin 3 on the toner sensor results in a 929 service error.
Diagnostic information 2-171
7002-xxx
Transfer roll service check
Service tip: The transfer roll is 51.02 mm (2.009 inch) circumference. Any print quality problems such as lines that are spaced 51.02 mm apart indicate you should check the transfer roll for damage and check for toner or foreign material buildup.
Service tip: The transfer roll assembly is part of the maintenance kit and is replaced when an
80 Scheduled
Maintenance
displays. Ask the customer if they have replaced the transfer roll recently.
CAUTION
Make sure the printer is unplugged before making any checks on the transfer roll or associated parts for personal safety and to prevent damage to the printer.
1
FRU
Transfer roll assembly
2 Left transfer arm assembly
3
4
Right transfer arm assembly
HVPS—917 Error code
Action
Check the transfer roll for toner buildup, surface damage to the roll, oil, or other contaminants on the surface of the roll. Replace the transfer roll as necessary.
Check the left transfer roll arm assembly to make sure it is fastened and locked in the down position. If the arm is not locked down, make sure the arm is not broken and locks into the EP frame correctly.
Check the left transfer arm assembly spring for proper operation.
Check the right transfer arm assembly to make sure it is fastened and locked in the down position. If the arm is not locked down, make sure the arm is not broken and locks into the EP frame correctly.
Check the right transfer arm assembly spring for proper operation.
For any background problems, ensure the contact to the HVPS board is correct and that there is approximately 0 ohms resistance between
Check the voltage at J15-3. The voltage changes from +24 V dc with the printer idle to 0 V dc when the printer runs the print test. If the voltage is incorrect, check the continuity of line J15-3 in the front cable harness to the HVPS. If there is no continuity, replace the cable harness. If there is continuity, replace the HVPS. If the problem continues, replace the system board.
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3. Diagnostic aids
This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem.
Accessing service menus
There are different test menus that can be accessed during POR to identify problems with the printer.
Diagnostics Menu 1. Turn off the printer.
2. Press and hold the 3 and 6 buttons simultaneously for about 10 seconds.
3. Turn on the printer.
4. Release the buttons after 10 seconds.
The Diagnostics Menu group consists of menus, settings, and operations that are used to diagnose various printer problems.
Note: While the Diagnostics menu group is active, all host interfaces are offline.
See
“Diagnostics Menu” on page 3-2
for more information.
Configuration Menu 1. Turn off the printer.
2. Press and hold the 2 and 6 buttons simultaneously for about 10 seconds.
3. Turn on the printer.
4. Release the buttons after 10 seconds.
The Configuration Menu group contains a set of menus, settings, and operations which are infrequently required by a user. Generally, the options made available in this menu group are used to configure a printer for operation.
See “Configuration menu (CONFIG MENU)” on page 3-24 for more information.
Diagnostic aids 3-1
7002-xxx
Diagnostics Menu
Entering Diagnostics Menu
1.
Turn off the printer.
2.
Press and hold 3 and 6 buttons simultaneously.
3.
Turn on the printer.
4.
Release the buttons after 10 seconds.
Available tests
The tests display on the operator panel in the order shown:
Note: Some menus are not available, depending on the configuration of the printer.
Diagnostics Menu tests
REGISTRATION
Top Margin
Bottom Margin
Left Margin
Right Margin
Quick Test
PRINT TESTS
Tray 1
Tray 2 (if installed)
Tray 3 (if installed)
Tray 4 (if installed)
Tray 5 (if installed)
MP Feeder
Envelope Feeder (if installed)
Printing Print Quality Test Pages
HARDWARE TESTS
Panel Test
Button Test
DRAM Test
CACHE Test
Parallel 1 Wrap (if installed)
( Note : This setting only appears if a parallel port is available through the PCI slot 1)
Serial 1 Wrap (if installed)
( Note : This setting only appears if a serial port is available through the PCI slot 1)
See
“Registration (printer)” on page 3-5
See “Input source tests” on page 3-7
See
“Printing Quality Pages” on page 3-7
See
See
See
“Parallel Wrap test” on page 3-10
See
“Serial Wrap test” on page 3-10
3-2 Service Manual
Diagnostics Menu tests (continued)
DUPLEX TESTS (if installed)
Quick Test
Top Margin
Sensor Test
Motor Test
Duplex Feed 1
Duplex Feed 2
INPUT TRAY TESTS
Feed Tests
Tray 1
Tray 2 (if installed)
Tray 3 (if installed)
Tray 4 (if installed)
Tray 5 (if installed)
Envelope Feeder
MP Feeder
Sensor Tests
Tray 1
Tray 2 (if installed)
Tray 3 (if installed)
Tray 4 (if installed)
Tray 5 (if installed)
Envelope Feeder
MP Feeder
OUTPUT BIN TESTS
Feed Tests
Standard Bin
Sensor Tests
Standard Bin
BASE SENSOR TEST
Toner Sensor
Input Sensor
Standard Bin Sensor
Upper Front Cover
Narrow Media
DEVICE TESTS
Quick Disk Test (model X646e)
Disk Test/Clean (model X646e)
Flash Test (if flash is installed)
See “Quick Test (duplex)” on page 3-11
See
“Top Margin (duplex)” on page 3-11
See
“Sensor Test (duplex)” on page 3-12
See “Motor Test (duplex)” on page 3-12
See
See
See
“Feed Tests (input tray)” on page 3-13
See
“Sensor Test (input tray)” on page 3-14
See
“OUTPUT BIN TESTS” on page 3-14
See
“BASE SENSOR TEST” on page 3-15
See “Quick Disk Test” on page 3-16
See
“Disk Test/Clean” on page 3-16
See
7002-xxx
Diagnostic aids 3-3
7002-xxx
Diagnostics Menu tests (continued)
PRINTER SETUP
Defaults
Printed Page Count
Perm Page Count
Serial Number
Envelope Enhance
Engine Setting 1 to 4
Model Name
Configuration ID
Edge To Edge
Par S Strobe Adj
PAR 1 STROBE ADJ (if additional parallel options are installed)
EP SETUP
EP Defaults
Fuser Temp
Fuser Page Count
Warm Up Time
Transfer
Print Contrast
Charge Roll
Gap Adjust
EVENT LOG
Display Log
Print Log
See
See
“Printed Page Count” on page 3-18
See
“Permanent Page Count” on page 3-18
See “Serial Number” on page 3-18
See
“Envelope Enhance” on page 3-18
See
“Engine Setting 1 through 4” on page 3-18
See “Configuration ID” on page 3-19
See
See “Parallel strobe adjustment (Par x Strobe Adj)” on page 3-19
See “Fuser Temperature (Fuser Temp)” on page 3-20
See “Fuser Page Count” on page 3-20
See “Warm Up Time” on page 3-20
See
See “Print Contrast” on page 3-21
See “Charge Roll” on page 3-21
See
Clear Log
SCANNER TESTS
ASIC Test
Feed test
Manual Registration
Sensor Tests
See
See
See
“Scanner Manual Registration” on page 3-23
Touch Exit Diag Menu to exit the Diagnostics Menu and
Resetting the Printer
displays. The printer performs a POR, and the printer returns to normal mode.
Exit
Diag Menu
Exit
Diag Menu
3-4 Service Manual
Registration (printer)
Print registration makes sure the printing is properly aligned on the page.
Models X644e/X646e Model X642e
REGISTRATION REGISTRATION
Top Margin
Bottom Margin
0
0
Top Margin
0
Top Margin
0
Left Margin 0
Right Margin 0
Top Margin
0
Quick Test
Top Margin
0
Submit
Submit
Back
Back
7002-xxx
The settings available are:
Description Value Direction of change
Bottom Margin -20 to +20
Each increment causes approximately 0.55 mm shift in the bottom margin.
Top Margin
Left Margin
-25 to +25
Each increment causes approximately 4 pels shift (at
600 dpi).
-25 to +25
Right Margin -10 to +10
A positive change compresses the image so it appears to move down the page, and a negative change moves the image up.
A positive change moves the image down the page and increases the top margin. A negative change moves the image up and decreases the top margin.
A positive change moves the image right, and a negative change moves the image left. No compression occurs.
A positive change moves the image right, and a negative change moves the image left.
Diagnostic aids 3-5
7002-xxx
To set print registration:
1.
Print the Quick Test page.
a.
Touch REGISTRATION from the Diagnostics Menu. b.
Touch to select Quick Test. You may need to scroll to the next page.
Retain this page to determine the changes you need to make to the margins settings. The diamonds in the margins should touch the margins of the page.
2.
To change the value of any of the margin settings:
• Touch to the right of the appropriate margin setting. The panel displays the setting's name in the header and [ setting's current value ] in a menu below the header row.
• Touch to decrease the value or to increase the value.
• Touch Submit to save the change, or Touch Back to cancel and return to the Diagnostics Menu.
• For model X642e, touch Submit to save all changed values.
The device prints a Quick Test page from the appropriate paper tray. While the Quick Test page prints,
Printing Alignment Page
appears on the LCD.
Quick Test
The Quick Test contains the following information:
• Margin settings
• Alignment diamonds at the top, bottom, and each side.
• Horizontal lines for skew adjustment
• General printer information, including current page count, installed memory, serial number, and code level.
To print the Quick Test page:
Note: Print the Quick Test Page on letter or A4 paper.
1.
Touch REGISTRATION from the Diagnostics Menu.
2.
Touch to select Quick Test.
The message
Quick Test Printing… appears on the display.
Once the Quick Test Page completes printing, the Registration screen displays again.
3.
Touch Back to return to the Diagnostics Menu.
3-6 Service Manual
7002-xxx
PRINT TESTS
Selections on the screen vary since only installed input sources are listed, followed by Printing Quality Test
Pages.
Input source tests
The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. The contents of the Print Test Page varies depending on the media installed in the selected input source.
Check each Test Page from each source to assist in print quality and paper feed problems.
To run the Print Test Page:
1.
Select PRINT TESTS from the Diagnostics menu.
2.
Select the media source to test:
Tray 1
Tray 2 (if installed)
Tray 3 (if installed)
Tray 4 (if installed)
Tray 5 (if installed)
MP Feeder (if installed)
Envelope Feeder (if installed)
3.
Select Single or Continuous .
• If Single is selected, a single page is printed.
• If Continuous is selected, printing continues until Stop is pressed to cancel the test.
If a source is selected that contains envelopes, an envelope test pattern is printed. If Continuous is selected, the test pattern is printed only on the first envelope.
Note: The Print Test Page always prints on one side of the paper, regardless of the duplex setting or the presence of a duplex option.
Touch Back to return to PRINT TESTS.
Printing Quality Pages
The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled. The print quality pages consist of four pages. Page one contains a mixture of graphics and text. Pages two and three only contain graphics. The last page is blank. If duplex is turned on, the pages are duplexed. The Print Quality Test pages are printed in English and must always be printed on letter, legal, or A4 paper.
To run the Print Quality Test Pages, touch beside Printing Quality Test Pages from PRINT TESTS. The message
Printing Quality Test Pages
is displayed.
Note: The print quality test pages can also be printed from the Configuration menu (CONFIG MENU), however, a cartridge must be installed with a machine class ID matching the machine class ID stored in NVRAM.
Additional diagnostic information may be printed on the pages when printing from DIAGNOSTICS.
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The following is included in the DIAGNOSTICS version of the print quality pages:
• Values from EP SETUP in DIAGNOSTICS, including:
Fuser temperature, warm up time, transfer, print contrast, and charge roll settings.
• Contents of the EVENT LOG from DIAGNOSTICS.
• Configuration information, including printer serial number, controller code level, engine code level, operator panel code level, font versions, and cartridge information.
• Default values for the QUALITY MENU settings used to print the pages.
HARDWARE TESTS
Select the following Hardware Tests from this menu:
• Panel Test
• Button Test
• DRAM Test
• CACHE Test
• Parallel 1 Wrap (if available)—models X644e/X646e
• Serial Wrap (if available)—models X644e/X646e
Panel Test
This test automatically toggles each pixel of the touchscreen through every contrast level beginning with the darkest and on to the brightest. This test continues until you press Stop ( ) .
Button Test
The Button Test verifies the operation of the buttons on the operator panel. When you select Button Test, a diagram of the operator panel appears on the panel. When you press a button on the operator panel, the corresponding touchscreen key is emphasized. Touch Back to cancel the test.
Models X644e/X646e Model X642e
1 2 3
4 5 6
7 8 9
* 0 =
<-
.
S G C
H T M
Back
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DRAM Test
The purpose of this test is to check the validity of DRAM memory, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly.
To run the DRAM Test:
1.
Touch to select DRAM Test from the menu.
The message
DRAM Test Testing…
displays. Then the message
Resetting Printer
appears, and the power indicator light blinks red.
2.
Turn the printer off and on. While the DRAM test executes, the power indicator blinks green.
The following type of message appears:
DRAM Test <### P:###### F:####
• xxx represents the installed DRAM size.
• P: ###### represents the number of times the memory test has passed and finished successfully.
Initially 000000 displays with the maximum pass count being 999,999.
• F: ##### represents the number of times the memory test has failed and finished with errors. Initially
0000 displays with the maximum fail count being 99,999. Initially only four digits appear, but additional digits appear as needed.
Each time a test is completed, the number of pass and failures increments. If the test fails, the message
Failure
displays for approximately three seconds, and the failure count increases by one.
The test continues until all standard and optional DRAM is tested. Once the maximum pass count or fail count is reached, the test is stopped, the power indicator is turned on solid, and the final results display.
To stop the test before completion, turn the MFP off.
CACHE Test
This test is used to verify the printer processor cache.
To run the CACHE Test:
1.
Touch from HARDWARE TESTS.
The message
CACHE Test Testing…
displays. Then the message
Resetting Printer
appears.
2.
The printer automatically performs a Power On Reset (POR). While the CACHE test executes, the power indicator blinks green.
The following type of message appears:
CACHE Test <### P:###### F:####
• P: ###### represents the number of times the cache has passed and finished successfully. Initially
000000 displays with the maximum pass count being 999,999.
• F: ##### represents the number of times the cache has failed and finished with errors. Initially 0000 displays with the maximum fail count being 99,999. Initially only four digits appear, but additional digits appear as needed.
Each time a test is completed, the number of passes and failures increments. If the test fails, the message
Failure
displays for approximately three seconds, and the failure count increases by one.
The test continues until all of the printer processor’s cache has been tested. Once the maximum pass count or fail count is reached, the test is stopped, the power indicator is turned on solid, and the final results display.
To stop this test before completion, turn the MFP off.
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Parallel Wrap test
This test is used with a wrap plug to check operation of the parallel port hardware. Each parallel signal is tested.
Use Parallel Wrap for the standard parallel port, Parallel 1 Wrap if a parallel port is available by PCI slot 1, or
Parallel 2 Wrap if a parallel port is available by PCI slot 2.
To run the Parallel Wrap tests:
1.
Disconnect the parallel interface cable, and install the wrap plug (P/N 1319128).
2.
Select Parallel Wrap, Parallel 1 Wrap, or Parallel 2 Wrap from the HARDWARE TESTS menu.
The power indicator blinks green indicating the test is in progress. The test runs continuously until a maximum number of tests is reached.
P:###### F:####
• P: ###### represents the number of times the memory test has passed and finished successfully.
Initially 000000 displays with the maximum pass count being 999,999.
• F: ##### represents the number of times the memory test has failed and finished with errors. Initially
0000 displays with the maximum fail count being 999,999. Initially only four digits appear, but additional digits appear as needed.
Each time the test finishes, the screen updates. If the test passes, the pass counter increases by 1, however if the test fails, a message displays for approximately three seconds. Once the maximum count is reached, the test stops. The power indicator goes on solid, and the final results display.
To stop the test before completion, press Stop ( ).
Serial Wrap test
The serial wrap tests are used to check the operation of the serial port hardware using a wrap plug. Use Serial 1
Wrap if a serial port is available through PCI slot 1 and Serial 2 Wrap if the serial port is available through PCI slot 2.
To perform the Serial Wrap tests:
1.
Disconnect the serial interface cable, and install the serial wrap plug.
2.
Select Serial 1 Wrap or Serial 2 Wrap from HARDWARE TESTS.
The power indicator blinks green indicating the test is in progress. The test runs continuously until a maximum number of tests is reached.
P:###### F:####
• P: ###### represents the number of times the memory test has passed and finished successfully.
Initially 000000 displays with the maximum pass count being 999,999.
• F: ##### represents the number of times the memory test has failed and finished with errors. Initially
0000 displays with the maximum fail count being 999,999. Initially only four digits appear, but additional digits appear as needed.
Each time the test finishes, the screen updates. If the test passes, the pass counter increases by 1, however if the test fails, a message displays for approximately three seconds. Once the maximum count is reached, the test stops. The power indicator goes on solid, and the final results display.
To stop the test before completion, press Stop ( ).The message
Serial Wrap x Test Canceled
displays, and the printer returns to the HARDWARE TESTS menu.
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DUPLEX TESTS
Quick Test (duplex)
This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page. You can run one duplexed page ( Single ), or continue printing duplexed pages ( Continuous ) until Stop (
) is pressed. For information about changing the margin, see “Top
.
Note:
The paper you choose to print the page on should be either Letter or A4.
To run the Quick Test (duplex):
1.
Touch from DUPLEX TESTS.
2.
Touch or Continuous .
• The single Duplex Quick test cannot be canceled.
• The printer attempts to print the Quick Test Page from the default paper source. If the default paper source only supports envelopes, then the page is printed from Tray 1.
• Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet.
The single test stops automatically when a single duplex sheet is printed, and the continuous test continues until you press Stop ( ) .
Top Margin (duplex)
This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin. See
“Registration (printer)” on page 3-5 .
To set the Top Margin (duplex):
1.
Print the Quick Test (duplex): a.
Touch from DUPLEX TESTS.
b.
Select Single .
c.
Hold the page to the light to see the whether the top margin of the backside aligns with the top margin of the frontside.
2.
Select Top Margin from DUPLEX TESTS.
3.
Use the arrows to increase or decrease the current setting displayed on the touchscreen to select the margin setting:
[ setting's current value ] .
• Each increment shifts the duplex top margin by 1/100 of an inch.
•
The Top Margin (duplex) range is -20 to +20, and the default value is 0.
• An increase moves the top margin down and widens the top margin. A decrease moves the top margin upward and narrows the top margin.
4.
Touch Submit .
5.
Print the Quick Test (duplex) again to verify the adjustment. Repeat if necessary.
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Sensor Test (duplex)
This test is used to determine whether or not the duplex sensors and switches are working correctly. The test allows you to actuate the duplex input sensor located in the back part of the duplex unit and the duplex exit sensor located in the return paper path.
1.
Select Sensor Test from DUPLEX TESTS.
The message
Sensor Test Testing
displays.
2.
Manually actuate each of the duplex sensors. When the sensor/switch is closed,
CL
(closed) displays, and when the sensor/switch is open,
OP
(open) displays.
• Duplex input sensor
• Duplex exit sensor
3.
Press Stop ( ) to exit the test.
Motor Test (duplex)
This test lets you test the duplex option paper feed drive system, and verify that the power and velocity values are acceptable. The duplex runs the DC motor at high speed and low speed, taking an average of the power
(PWM) required for each speed and calculating the KE value.
To run the Motor Test (duplex):
1.
Select Motor Test from DUPLEX TESTS.
The power indicator light blinks, and the message
Motor Test Testing
displays.
2.
When the motor stops, the results are displayed.
DUPLEX MOTOR AA
BB CC DD EE FF
• AA—00 indicates success, and any other value indicates failure.
• BB—average PWM for the high speed portion of the test. The results should be in the range of 20 through 3F inclusively (hex)
• CC—average PWM for the low speed portion of the test The results should be in the range of 3A through 5D inclusively (hex)
• DD— minimum PWM for the low speed portion of the test. The results should be in the range of 11 through 1F inclusively (hex)
• Ignore bytes EE and FF .
If the test fails, remove the drive belt from the duplex DC motor, and run the motor test again. For the duplex DC motor to pass the test, the following results must display:
• AA = 00
• BB = in the range of 29 through 3E inclusively (hex)
• CC = in the range of 35 through 51 inclusively (hex)
• DD = in the range of 0C through 13 inclusively (hex)
For the duplex drive system to pass the test, the following results must display:
• AA = 00
• BB = in the range of 29 through 3F inclusively (hex)
• CC = in the range of 3A through 5D inclusively (hex)
• DD = in the range of 11 through 1F inclusively (hex)
3.
Touch Back or press Stop ( ) to exit the test.
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Duplex Feed 1
This test feeds a blank sheet of paper to the duplex paper stop position 1. This test can be run using any of the supported paper sizes.
To run the Duplex Feed 1 Test:
1.
Touch from DUPLEX TESTS.
The power indicator blinks while the paper is feeding, and the message
Duplex Feed 1 Feeding
… displays.
The message
Duplex Feed 1 Clear Paper
displays when the paper reaches paper stop position 1, and the power indicator turns on solid.
2.
Remove the media from the duplex unit, and clear the message on the operator panel by touching Back or pressing Stop ( ).
Duplex Feed 2
This test feeds a blank sheet of paper to the duplex paper stop position 2. This test can be run using any of the supported paper sizes.
To run the Duplex Feed 2 Test:
1.
Touch from DUPLEX TESTS.
The power indicator blinks while the paper is feeding, and the message
Duplex Feed 2 Feeding
… displays.
The message
Duplex Feed 2 Clear Paper
displays when the paper reaches the duplex paper stop position
2, and the power indicator turns on solid.
2.
Remove the media from the duplex unit, and clear the message on the operator panel by touching Back or pressing Stop ( ).
INPUT TRAY TESTS
Feed Tests (input tray)
This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder. The paper is placed in the output bin.
To run the Input Tray Feed Tests:
1.
Touch Feed Tests from INPUT TRAY TESTS.
2.
Touch to select the input source from the sources displayed on the Feed Tests menu. All installed sources are listed.
3.
Touch to select either Single or Continuous.
• Single —feeds one sheet of media from the selected source.
• Continuous— media continues feeding from the selected source until Stop ( ) is pressed.
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Sensor Test (input tray)
This test is used to determine if the input tray sensors are working correctly. To run the Input Tray Sensor Test:
1.
Touch to select the Sensor Test from INPUT TRAY TESTS.
2.
Touch to select the input source from the sources displayed on the Sensor Test menu. All installed sources are listed.
3.
Select the sensor to test. Various sources have different combinations of sensors. See the table below:
Tray sensor support by source
Source
Tray 1
Tray 2
Tray 3
Tray 4
Tray 5
Multipurpose tray
Envelope feeder
Empty
(Input tray empty sensor)
✓
✓
✓
✓
✓
✓
✓
Low
(Input tray paper low sensor)
✓
✓
✓
✓
✓ passThru
(Input tray pass thru sensor)
✓
✓
✓
✓
✓
[ sensor selected ]
=Open
displays.
• Empty—Input tray empty sensor
•
Low—Input tray paper low sensor
• passThru—Input tray pass thru sensor
4.
Once this message displays, the servicer can manually actuate each sensor. The tray empty sensor can be actuated by hand, however a sheet of paper can be used to cover the pass thru sensor. When the sensor is closed,
Closed
displays; when the sensor is open,
Open
displays.
5.
Press Stop ( ) to exit the test.
OUTPUT BIN TESTS
Feed Tests (output bins)
Use these tests to verify that media can be fed to a the standard output bin. No information is printed on the media fed to the output bin because the printhead is not engaged during this test. These tests can use any media size or envelope supported by the printer.
To run the Feed Tests for the output bins:
1.
Touch from the OUTPUT BIN TESTS.
2.
Touch to select the output bin you want the paper to exit into.
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3.
Touch to select either Single or Continuous.
• Single —feeds one sheet of media from the selected source.
• Continuous —media continues feeding from the selected source until Stop ( ) is pressed.
Touch Back to return to OUTPUT BIN TESTS.
Sensor Test (standard output bin)
This test is used to verify if the standard bin sensor is working correctly.
To run the Sensor Test for the standard bin:
1.
Touch from OUTPUT BIN TESTS.
2.
Touch from Sensor Tests.
3.
Manually actuate the bin sensor by moving the flag in and out of the sensor and the display changes.
The following screen is displayed:
Bin Empty: empty or
Bin Empty: full.
4.
Press Stop ( ) to exit the test.
BASE SENSOR TEST
This test is used to determine if the sensors located inside the printer are working correctly.
To run the Base Sensor Test:
1.
Select BASE SENSOR TEST from the DIAGNOSTICS menu.
The following sensors are listed:
•
Exit—Exit sensor
• Front Door—Front door sensor
•
Input—Input sensor
• NarrowMedia—Output (exit) sensor
•
Toner Level—Toner level sensor (remove the cartridge and replace to actuate the sensor)
2.
Manually actuate the sensors to verify that each sensor switches from
Open
to
Closed
.
3.
Press Stop ( ) to exit the test.
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DEVICE TESTS
Quick Disk Test
This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the block is good, the saved data is written back to the disk.
To run the Quick Disk Test:
1.
Touch from DEVICE TESTS.
The power indicator blinks while the test is in progress, and quick
Disk Test Testing
… displays.
• Quick Disk Test/Test Passed
message displays if the test passes, and the power indicator turns on solid.
• Quick Disk Test/Test Failed
message displays if the test failed, and the power indicator turns on solid.
2.
Press Stop ( ) to return to the Device Tests menu.
Disk Test/Clean
Warning: This test destroys all data on the disk and should not be attempted on a good disk. Also note that this test may run approximately 1½ hours depending on the disk size.
To run the Disk Test/Clean Test:
1.
Touch from the Device Tests menu.
Contents will be lost. Continue?
message displays to warn the user that all contents on the disk will be lost.
2.
Touch Yes to continue and No to exit.
If Yes is selected, the following screen displays and updates periodically indicating the percentage of test completed.
Formatting Disk
1/1 0%
DO NOT POWER OFF
The power indicator blinks during the test.
Note: The test can NOT be canceled.
3.
Once the test is complete, the power indicator turns on solid, and either the message
Disk Test/Clean
Test Passed
or
Disk Test/Clean Failed
appears. If the message indicates failure, the disk is unusable.
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Flash Test
This test verifies the functioning of the flash device by writing and reading data on the flash to test the flash.
Warning: This test destroys all data on the flash because the flash is unformatted at the end of the test. To reformat the flash, the servicer or the user must use FORMAT FLASH from the UTILITIES MENU.
To run the Flash Test:
1.
Touch from DEVICE TESTS.
The message
Contents will be lost. Continue? displays to warn the user that all contents on the flash device will be lost.
2.
To exit the test immediately and return to the Device Tests menu, touch No. To continue, touch Yes .
The power indicator blinks while the test is running, and the message
Flash Test Testing
… displays.
Once the test is complete, the power indicator turns on solid, and either the message
Flash Test Test
Passed
or
Flash Test Test Failed
displays.
3.
Touch Back or press Stop ( ) to return to DEVICE TESTS.
PRINTER SETUP
PRINTER SETUP
Defaults
Printed Page Count
Models X644e/X646e
US
127
127 Permanent Page Count
Serial Number xxxxxxx
Envelope Enhance
Engine Setting 1
Medium
0
PRINTER SETUP
Defaults
U.S.
Printed Page Count
127
Perm Page Count
127
Serial Number xxxxxxx
Model X642e
Submit
Back
Submit
Back
The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to display these additional menus.
Note: If you make changes, touch Submit to make the change effective.
Defaults
US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US factory defaults.
The settings affected include paper size, envelope size, PCL symbol set, code pages, and units of measure.
Warning: Changing this setting resets the printer to factory defaults, and data may be lost. It cannot be undone.
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Printed Page Count
The page count can only be viewed and cannot be changed.
Touch Back to return to Diagnostics Menu.
Permanent Page Count
The permanent page count can only be viewed and cannot be changed.
Touch Back to return to Diagnostics Menu.
Serial Number
The serial number can only be viewed and cannot be changed.
Touch Back to return to Diagnostics Menu.
Envelope Enhance
This setting affects the level of the fuser solenoid.
To set Envelope Enhance:
1.
The current value is displayed:
[ setting's current value ]
The values are Low , Medium , and High . The default is Medium.
2.
Touch or to change the value.
Touch Back to return to Diagnostics Menu.
Engine Setting 1 through 4
Warning: Do not change these settings unless requested to do so by your next level of support.
Model Name
The model name can only be viewed and cannot be changed.
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Configuration ID
The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The configuration IDs are originally set at the factory when the printer is manufactured, however, the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever you replace the system board. The IDs consist of eight hexadecimal characters, including 0 through 9 and A through F.
Note: When the printer detects a Configuration ID that is not defined or invalid, the following occurs:
• The default standard model Configuration ID is used instead.
• Configuration ID is the only function available in DIAGNOSTICS.
• Unless the menu is in DIAGNOSTICS,
Check Config ID
displays.
To set the configuration ID:
1.
Touch from the Diagnostics Menu.
2.
Touch .
3.
Touch the keyboard icon to display a keyboard with 1 through 0 and a through f. The current values for
Configuration ID 1 and Configuration ID 2 are displayed.
• Use keys to type the numbers for the two configuration IDs.
• Use the left arrow to move over a digit from the right of the number toward the left.
• When the numbers are correct, touch Submit .
• If you have a question, touch the question mark icon.
• To exit without changing the numbers, touch Back .
Note: Be sure to touch Submit , or the number will not be changed.
Submitting Selection
displays, followed by the value for Configuration ID 1.
Note: If
Invalid ID
appears, the entry is discarded, and the previous Configuration ID 1 is displayed on the screen.
If the process is successful,
Submitting Selection
appears on the display, followed by the current value for Configuration ID 2.
4.
Restart the printer.
Edge to Edge
When this setting is On, the text and graphics are shifted to the physical edges of the paper for all margins.
When the setting is Off, the normal margins are restored.
Parallel strobe adjustment (Par x Strobe Adj)
This setting adjusts the amount of time the strobe is sampled in order to determine if the valid data is available on the parallel port. The range of values are from -4 to 6, and the default is 0 for Par S Strobe Adj ,
Par 1 Strobe Adj , and Par 2 Strobe Adj . After adjustment of 1 increment, the strobe samples 50 ns longer.
Diagnostic aids 3-19
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EP SETUP
Models X644e/X646e
EP SETUP
EP Defaults
Fuser Temp
Fuser Page Count
Warm Up Time
Normal
127
Transfer
Print Contrast
Medium
Medium
Submit
Back
EP SETUP
EP Defaults
Fuser Temp
Normal
Fuser Page Count
127
Warm Up Time
0
Submit
Model X642e
Back
The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to display these additional menus.
Note: If you make changes, touch Submit to make the change effective.
EP Defaults
This setting is used to restore each printer setting listed in EP SETUP to its factory default value. Sometimes this is used to help correct print quality problems.
To restore EP Defaults:
1.
Touch from EP SETUP.
2.
Touch to reset the values to the factory settings, and touch to select Do Not
Restore to exit without changing the settings.
Touch Back to exit without changing the settings.
Fuser Temperature (Fuser Temp)
This adjustment can be used to help solve some customer problems with paper curl on low grade papers and problems with letterheads on some types of media.
The fuser temperature can be adjusted to: Normal, Lower, Lowest. The default is Normal.
Touch Back to return to Diagnostics Menu.
Fuser Page Count
The fuser page count can only be viewed and cannot be changed.
Touch Back to return to Diagnostics Menu.
Warm Up Time
You can change the amount of time the printer warms up before allowing pages to print by changing this setting from 0 to 5. The factory sets the warm up at 0 or no warm up time. This time period lets the backup roll heat up and helps reduce curl in some environments.
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Touch Back to return to Diagnostics Menu.
Transfer
The transfer can be adjusted to Low, Medium, or High. The default setting is Medium.
Touch Back to return to Diagnostics Menu.
Print Contrast
The print contrast setting controls the developer voltage offset.
The print contrast can be adjusted to Low, Medium, or High. The default setting is Medium.
Touch Back to return to Diagnostics Menu.
Charge Roll
The charge roll can be adjusted to Low, Medium, or High. The default setting is Medium.
Touch Back to return to Diagnostics Menu.
Gap Adjust
The setting adjusts the minimum gap between sheets. Increasing this value may reduce curl of some printed media and eliminate some output bin stacking problems. However, increasing this value also results in slower overall performance, measured in pages per minute. The range of values is 0 to 255, and the default value is 0.
Touch Back to return to Diagnostics Menu.
EVENT LOG
Display Log
The event log provides a history of printer errors. It contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1, and the oldest error displays in position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is discarded. Identical errors in consecutive positions in the log are entered, so there may be repetitions. All 2 xx and 9 xx error messages are stored in the event log.
To view the event log:
1.
Touch from EVENT LOG.
Up to three error codes display at a time. Touch to display additional information, if available.
2.
Touch Back to return to the EVENT LOG menu.
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Print Log
Additional diagnostic information is available when you print the event log from Diagnostics Menu rather than
Configuration Menu.
The Event Log printed from Diagnostics Menu includes:
• Detailed printer information, including code versions
• Time and date stamps
• Page counts for most errors
• Additional debug information in some cases
The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis.
To print the event log: select from EVENT LOG.
Clear Log
Use Clear Log to remove the current information in the Event Log. This affects both the viewed log and the printed log information.
1.
Touch from the Event Log menu.
2.
Touch to clear the Event Log, or touch to select NO to exit the Clear Log menu. If
YES is selected,
Deleting EVENT LOG
displays on the screen.
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SCANNER TESTS
ASIC Test
A pattern appears and
ASIC Test Passed
displays. If xxxxxx displays, the test was unsuccessful.
Press Stop ( ) to return to the SCANNER TESTS menu.
Feed Test
To run the Scanner Feed test:
1.
Touch to select Feed Test from the SCANNER TESTS menu.
2.
The panel displays the setting's current value [ setting's current value ] . Use the arrows to select from
Letter, Legal, or A4.
3.
Touch START to begin.
Feed Test Testing…
displays.
Press 4 to exit the test.
4.
Touch Back to return to the Diagnostics Menu.
Scanner Manual Registration
Note: Do not change these settings unless requested to do so by your next level of support
Sensor Tests
The following tests are available:
ADF cover Open
ADF Exit Sensor
ADF Interval
ADF Jam Removal
ADF Paper Present
FB Cover Open
Home Sensor
SCAN_QRY_PAPER_SIZE_ADF_LONG
SCAN_QRY_PAPER_SIZE_ADF_WIDTH1
SCAN_QRY_PAPER_SIZE_ADF_WIDTH2
SCAN_QRY_PAPER_SIZE_ADF_WIDTH3
SCAN_QRY_PAPER_SIZE_FB_LONG
SCAN_QRY_PAPER_SIZE_FB_MEDIUM
SCAN_QRY_PAPER_SIZE_FB_SHORT
SCAN_SENSOR_FIRST_SCAN_BIT
SCAN_SENSOR_SECOND_SCAN_BIT
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Configuration menu (CONFIG MENU)
Entering Configuration Menu
1.
Turn off the printer.
2.
Press and hold 2 and 6 buttons simultaneously.
3.
Turn on the printer.
4.
Release the buttons after 10 seconds.
Available menus
Note: Some menus are not available, depending on the configuration of the printer.
Maintenance Page Counter
Reset Maintenance Counter
Print Quality Pages
SIZE SENSING
Panel Menus
PPDS Emulation
Factory Defaults
Energy Conserve
Min Copy Memory
Format Fax Storage
ADF Edge Erase
FB Edge Erase
Automatic Scanner Registration
EVENT LOG (print log only)
Paper Prompts
Env Prompts
Jobs On Disk
Disk Encryption
Wipe Disk
Font Sharpening
Require Standby
LES App[lications
Key Repeat Initial Delay
Key Repeat Rate
Wiper Message
See
“Maintenance Page Count” on page 3-25
See “Reset Maintenance Counter” on page 3-25
See “Print Quality Pages” on page 3-26
See
See “Panel Menus” on page 3-27
See “PPDS Emulation” on page 3-27
See “Factory Defaults” on page 3-28
See
“Energy Conserve” on page 3-28
See
“Min Copy Memory” on page 3-29
See
“Format Fax Storage” on page 3-29
See “ADF Edge Erase” on page 3-29
See “FB Edge Erase” on page 3-30
See
“Automatic Scanner Registration” on page 3-30
See
See “Paper Prompts” on page 3-31
See
“Envelope Prompts” on page 3-32
See
See “Disk Encryption” on page 3-32
See
See “Font Sharpening” on page 3-34
See
“Require Standby” on page 3-34
See “LES Applications” on page 3-34
See
“Key Repeat Initial Delay” on page 3-35
See
“Key Repeat Rate” on page 3-35
See “Wiper Message” on page 3-35
Touch Exit Config Menu to exit the Configuration Menu and
Resetting the Printer
displays. The printer performs a POR, and the printer returns to normal mode.
Exit
Config Menu
Exit
Config Menu
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Maintenance Page Count
The current value for the maintenance page counter is displayed. This counter tracks printer usage. A print job containing a single page increments the counter by one and a duplex page by two. At 300,000, the customer is reminded that the printer requires scheduled maintenance. This counter is reset by the servicer after a 80
Scheduled Maintenance message displays and a maintenance kit is installed. See
“Maintenance kit” on page 6-1 for the part number.
To view the maintenance page count touch to select Maint Cnt Value from the Configuration Menu. The value is displayed and cannot be changed.
Touch Back to return to the main Configuration Menu.
Reset Maintenance Counter
After scheduled maintenance, the servicer needs to reset the page counter.
To reset the maintenance page count to zero:
1.
Touch to select Reset Maintenance Counter from the Configuration Menu.
2.
Touch Yes to reset the counter or touch No to exit without resetting the counter.
Reset Maintenance Counter
Yes No
The message
Reset Maint Cnt=Reset
displays momentarily. When the reset operation is complete, the menu returns to the main Configuration Menu.
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Print Quality Pages
The print quality test pages can be printed from either the Diagnostics Menu or Configuration Menu (CONFIG
MENU). When printed from the Diagnostics Menu, additional information is included, and the print cartridge lockout is bypassed. See
“Print Quality Pages” on page 3-26
. Additional configuration information may be included on the print quality pages which is not included on the print menu page.
To print the Print Quality Test Pages, touch to select Prt Quality Pgs from Configuration Menu. The message
Printing Quality Test Pages is displayed.
The following is printed:
• Settings from EP SETUP from the Diagnostics Menu:
Fuser temperature, warm up time, transfer, print contrast, and charge roll settings.
• Contents of the EVENT LOG from the Diagnostics Menu.
• Printer configuration information:
Printer serial number, controller code level, engine code level, operator panel code level, smart option code levels, font versions, and so on.
Values for the QUALITY MENU settings used to print the pages.
The print quality test consists of four pages. Page one contains a mixture of graphics and text. Pages two and three only contain graphics. Page four is blank. If duplex is turned on, the pages are duplexed. The Print Quality
Test pages are printed in English and must always be printed on letter, legal, or A4 paper.
SIZE SENSING
This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing.
Paper source
Tray 1 (integrated)
Multipurpose feeder
250-sheet drawer
500-sheet drawer
2000-sheet drawer
250-sheet duplex
500-sheet duplex
Envelope feeder
Size sensing
✓
✓
✓
✓
When the setting is Auto, every input option equipped with size sensing hardware automatically registers what size media it contains. When the setting is Off, the media size detected by hardware is ignored. The media size can be set by the operator panel or the data stream.
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To change the size sensing setting:
1.
Touch from the Configuration Menu.
2.
The panel displays the setting's name in the header and [ setting's current value ] below the header row. Touch or to change the setting. The selections are Auto and Off.
3.
Touch Submit to save your change.
Touch Back to exit without changing the value.
Panel Menus
To change the Panel Menus setting:
1.
Touch from the Configuration Menu.
2.
The panel displays the setting's name in the header and [ setting's current value ] below the header row. Touch or to change the setting. The selections are Disable and Enable. The default is Enable.
3.
Touch Submit to save your change.
Touch Back to exit without changing the value.
PPDS Emulation
This menu item allows the user to enable or disable PPDS emulation data stream. When this setting is enabled, the following settings are also changed:
•
SmartSwitch settings for each port are turned off.
• The printer language is changed to PPDS Emulation.
Users can still switch languages on the operator panel and through the PJL data stream.
To change the PPDS Emulation setting:
1.
Touch from the Configuration Menu.
2.
The panel displays the setting's name in the header and [ setting's current value ] below the header row. Touch or to change the setting. The selections are Activate and Deactivate. The default is
Deactivate.
3.
Touch Submit to save your change.
Touch Back to exit without changing the value.
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Factory Defaults
This setting enables a user to restore all the printer settings to the original factory settings. Selections are
Restore Base, Restore Network , or Restore LES . Restore LES enables you to remove all Lexmark Embedded
Solutions applications (LES).
Network does not appear unless you have a network printer. The following settings are not changed:
• Display language
• Settings in the NETWORK/PORTS MENU group.
To reset factory defaults:
1.
Touch to select Factory Defaults from the Configuration Menu.
2.
Touch to select either Restore Base, Restore Network, or Restore LES.
Note: There is no confirmation, and selecting one of these settings immediately takes effect. The MFP restarts and returns to Ready state.
Restoring Factory Defaults
and then
Resetting the Device
are displayed.
Factory Defaults
Restore Base
Restore Network
Restore LES
Back
Energy Conserve
This menu controls what values appear on the Power Saver menu. If Off is selected in Energy Conserve menu, then Disabled appears in the Power Saver menu, and Power Saver can be turned off. If On is set in Energy
Conserve, the Power Saver feature cannot be disabled.
1.
Touch from the Configuration Menu.
2.
The panel displays the setting's name in the header and [ setting's current value ] below the header row. Touch or to change the setting. The selections are On and Off. The default is On.
3.
Touch Submit to save your change.
Touch Back to exit without changing the value.
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Min Copy Memory
1.
Touch Min Copy Memory from the Configuration Menu.
The panel displays the setting's name in the header and [ setting's current value ] below the header row.
2.
Touch or to change the setting.
For example, the values may be 25 MB, 35 MB, 50 MB, and 100 MB. The default is 25 MB. Values will only be displayed if the amount of installed DRAM is at least twice the amount of the value, that is, at least
200 MB of installed DRAM is required to display the 100 MB selection.
3.
Touch Submit to save your change.
Touch Back to exit without changing the value.
Format Fax Storage
This setting enables you to format the non-volatile storage used for storing faxes.
To change this setting, touch to select Format Fax Storage from the Configuration Menu.
Formatting Fax
Flash DO NOT POWER OFF
appears on the LCD while the format operation is active.
Note: If an advanced password has been established, you must enter this password in order to change the setting.
ADF Edge Erase
The ADF Edge Erase and FB Edge Erase settings specify, in millimeters, the size of a border around the scanned image that will be erased. For copies, the printed page will have a 2 mm no-print border. The larger of the 2 mm no-print border and the Edge Erase setting will be used in this situation.
To change this setting:
1.
Touch to select ADF Edge Erase from the Configuration Menu.
The panel displays the setting's name in the header and [ setting's current value ] below the header row.
2.
Touch to increase the value or to decrease the value.
The values are 0 through 6. The default is 3.
3.
Touch Submit to save the change.
Touch Back to cancel and return to the Configuration Menu.
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FB Edge Erase
The ADF Edge Erase and FB Edge Erase settings specify, in millimeters, the size of a border around the scanned image that will be erased. For copies, the printed page will have a 2 mm no-print border. The larger of the 2 mm no-print border and the Edge Erase setting will be used in this situation.
To change this setting:
1.
Touch from the Configuration Menu.
The panel displays the setting's name in the header and [ setting's current value ] below the header row.
2.
Touch to increase the value or to decrease the value.
The values are 0 through 6. The default is 3.
3.
Touch Submit to save the change.
Touch Back to cancel and return to the Configuration Menu.
Automatic Scanner Registration
To perform the Automatic Scanner Registration:
1.
Obtain two pieces of colored paper (A4 or letter) for the automatic registration. Use a light blue sheet or other solid color paper.
Note: Always store the colored sheets so they do not become creased or torn. The sheets can be used if you need to run Automatic Scanner Registration at another time.
2.
Scroll through the menus using the down arrow, and select Automatic Scanner Registration from the
Configuration Menu.
Please place a piece of dark colored paper on the Flatbed and in the ADF
Start
Back
3.
Place a colored piece of paper in the ADF, making sure the edge guides are properly adjusted. Place another piece of paper (A4 or letter) on the flatbed. Touch Start .
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4.
The touchscreen displays
DO NOT POWER OFF Scanner Registration.
When complete, a screen similar to the following should appear:
Scanner registration successfully completed
Continue
5.
Touch Continue .
Note: If the Automatic Scanner Registration displays a failure, repeat the process making sure the paper is aligned as correctly as possible. If the process fails again, contact the next level of support.
EVENT LOG
The event log provides a history of printer errors. The event log can only be printed in CONFIG MENU.
Additional options are available in DIAGNOSTICS. See
To print the event log:
1.
Touch from Configuration Menu.
2.
Touch to print the log.
Printing Event Log. displays on the touchscreen.
3.
Touch Back to return to EVENT LOG.
Note: An event log printed from the CONFIG MENU will not contain debug information or secondary codes for
900 service errors. However, the event log printed from DIAGNOSTICS mode does include this information.
Paper Prompts
When a tray is out of the indicated paper size, a prompt is sent to the user to load paper in a tray. This setting controls the tray the user is directed to fill.
1.
Touch from the Configuration Menu.
The panel displays the setting's name in the header and [ setting's current value ] below the header row.
2.
Touch or to change the value.
The values are Auto (default), MP Feeder, and Manual Paper.
3.
Touch Submit to save the change.
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Envelope Prompts
This setting controls the tray the user is directed to refill when a specific envelope size is out. The selections are
Auto (default), MP Feeder , and Manual Env .
1.
Touch from the Configuration Menu.
The panel displays the setting's name in the header and [ setting's current value ] below the header row.
2.
Touch or to change the value.
The values are Auto (default), MP Feeder, and Manual Envelope.
3.
Touch Submit to save the change.
Jobs On Disk
Model X646e only. If the hard disk is installed, Jobs On Disk allows the user to delete buffered jobs saved on the disk. The values are Delete and Do Not Delete .
To delete jobs saved on the disk:
1.
Touch to select Jobs On Disk from the Configuration Menu.
2.
Touch to decrease the setting's value.
3.
Touch or to change the value.
Touch Back to cancel and return to the Configuration Menu.
Disk Encryption
Model X646e only. If a hard disk is installed, Disk Encryption selects whether the data on the disk is encrypted or not. The values are Disable and Enable .
This setting determines if the printer encrypts the information that it writes to the hard disk. The values are
Disable and Enable.
Warning: If the value is changed from Enable to Disable or from Disable to Enable, then the printer completely formats the hard disk. All information on the disk will be unrecoverable.
To change this setting:
1.
Touch from the Configuration Menu.
Note: If an advanced password has been established, you must enter this password in order to change the setting. If no advanced password exists, you can establish one by using the keyboard that appears on the LCD.
2.
Touch next to either Enable or Disable .
If you remove an encrypted disk from a device and then try to install another disk,
Disk Corrupted.
Reformat? appears on the LCD. You can format the newly installed disk or remove it from the device.
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3.
Contents will be lost. Continue?
appears on the touchscreen. Touch No to cancel or Yes to proceed. If you select Yes, the printer performs the selected action on the hard disk. The following graphic appears when the encryption process is selected:
The panel provides many progress indicators during the two-stage process.
• 1/2 indicates that the process is currently in the first stage.
• 0% indicates the progress of the current stage of the process.
• The progress bar indicates the overall completion of the entire process by filling in throughout each separate stage.
When the first stage of either process completes, the printer displays either of the following graphics depending on the process selected and then begins the second stage of the process:
The entire process is complete when the progress bar appears completely shaded and the percentage indicator shows 100%. After completion, the panel returns to Disk Encryption.
Wipe Disk
This setting provides you with a tool for erasing the contents of a disk.
Warning: Wipe Disk removes a disk's data in such a way that it cannot be recovered.
To change this setting:
1.
Touch from Configuration Menu.
Note: If an advanced password has been established, you must enter this password in order to change the setting. If no advanced password exists, you can establish one by using the keyboard that appears on the LCD.
2.
Touch .
Contents will be lost. Continue?
appears on the touchscreen.
3.
Touch Back to return to EVENT LOG.
4.
Touch Yes to continue, or touch No to exit.
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Font Sharpening
This setting allows a user to set a text point size below which the high frequency screens are used when printing font data. For example, at the default 24, all text in font sizes 24 and less will use the high frequency screens.
The values for this setting range from 0 to 150, and the default value is 24. This setting affects PostScript, PCL, and XL.
To change this setting:
1.
Touch from the Configuration Menu.
2.
Touch to increase the value or to decrease the value.
3.
Touch Back to cancel and return to the Configuration Menu.
4.
Touch Submit to save the change.
This function is not supported when the device generates output at 600 dpi resolution.
Require Standby
This setting determines if the Standby Mode is On or Off. The default is On.
If Standby Mode is on, the printer begins functioning in Standby Mode when it remains idle for an amount of time. The Standby Mode enables the printer:
• To consume less energy than when operating in normal mode but not as little as when operating in Power
Saver
• To return to the Ready state more quickly than when operating in Power Saver
To change this setting:
1.
Touch from the Configuration Menu.
2.
Touch Back to cancel and return to the Configuration Menu.
3.
Touch Submit to save the change.
LES Applications
This disables all installed Lexmark Embedded Solution applications. The default is Enabled.
To change this setting:
1.
Touch from the Configuration Menu.
Note: If an advanced password has been established, you must enter this password in order to change the setting. If no advanced password exists, you can establish one by using the keyboard that appears on the LCD.
2.
Touch Back to cancel and return to the Configuration Menu.
3.
Touch Submit to save the change.
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Key Repeat Initial Delay
When a key is touched repeatedly, this is the delay before the key begins repeating. The delay ranges from 0.25 seconds to 5 seconds. The default is 1 second. Values are given in increments of 0.25 seconds.
To change this setting:
1.
Touch from the Configuration Menu.
2.
Touch to increase the value or to decrease the value.
3.
Touch Submit to save the change.
Touch Back to cancel and return to the Configuration Menu.
Key Repeat Rate
This is the number of times per second that a repeating key will repeat. The range is 1–100, with a default of 15 times per second.
To change this setting:
1.
Touch from the Configuration Menu.
2.
Touch to increase the value or to decrease the value.
3.
Touch Submit to save the change.
Touch Back to cancel and return to the Configuration Menu.
Wiper Message
To change this setting:
1.
Touch from the Configuration Menu.
2.
Touch or to change the value. The values are On (default) and Off.
3.
Touch Submit to save the change.
Touch Back to cancel and return to the Configuration Menu.
Exit Configuration Menu
Touch Exit Config Menu to exit the Diagnostics Menu and
Resetting the Printer
displays. The printer performs a POR, and the printer returns to normal mode.
Exit
Config Menu
Exit
Config Menu
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Theory
Autocompensator operation
The autocompensator is a paper pick device that generates its own normal force. This force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary, therefore no special trays are needed for card stock or labels. The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm. This movement produces a downward force at the pick rolls. The friction between the pick roll and the paper produces a frictional locking condition. If the paper is physically held and not allowed to feed, then the motor stalls. Slippage between the roll and the paper is theoretically impossible. When the motor is energized, the pick rolls are driven down into the stack, increasing the normal force and drive force until the bending strength of the paper is overcome and the paper bends and moves up the dam.
Once this critical threshold is achieved, the normal force remains at a level just high enough to reliably feed the paper. Rather than having a fixed spring force for feeding all weights of paper like the D-roll, this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness. High normal force is one of the most significant contributors to double feeding paper. The pick arm is counterbalanced by an extension spring located on the pick arm to reduce weight in the rest state. This spring is factory set to exert no more than ten to fifteen grams on the stack. This is as light as can be realistically set and always guarantee there is some force to start the autocompensating phenomena. This spring is not to be considered an adjustment for feeding problems unless it is obvious that the pick arm cannot fall all the way down to the bottom of the tray or has come loose. Poor gear efficiency can cause the arm to generate higher than normal forces. If the pick assembly is noisy, replacement may be required. The arm must pivot freely through its full range of motion. On 500-sheet trays, there are wrap springs located on the pivot arbors of the arm. These springs help prevent the arm from bouncing. If the arm appears to be binding or sticky near the bottom of the tray, these springs may be the problem. Reducing the tension on the counterbalance spring may be used as a temporary fix to get additional weight at the bottom, until the pick assembly can be replaced. However, the counterbalance spring is not to be considered an adjustment for feeding problems.
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Autoconnect system, paper tray options, envelope feeder—electrical
Autoconnect cabling and connectors
The printer options make electrical connection automatically, requiring no external cables when the option is mechanically installed under the printer. Communication between the option and the printer stops when you remove an option. The printer no longer recognizes the option and deletes associated messages. Each installed option below the printer provides an electrical autoconnect to the option attached below it. We do not recommend to attach or “Hot Plug” any options with the printer power turned on.
Duplex Option
The duplex option interface is a six pin autoconnector that provides a +24 V dc, +24 V dc return, serial interface transmit signal, serial interface receive signal, and two ground pins. The duplex option receives the +24 V dc from the printer for the duplex motors and also converts the voltage to +5 V dc for duplex electronics.
Duplex chassis grounding is provided from the printer to the duplex option through a ground spring attached to the frame and base of the printer. The ground connection is automatically made when the option is installed below the printer.
The paper input sensor is located in the rear of the duplex option under the input paper guide. The paper exit sensor is located on the left frame assembly.
Option microcode
The options are “Smart Options” or options that have a system board. The option system board has a microprocessor that controls the option mechanism. A software architecture is provided that controls the option and communicates information such as paper path status, sensor status, motor status, and so on to the printer.
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Paper feed jams
By carefully selecting print media and loading it properly, you should be able to avoid most paper jams. For more
information on avoiding paper jams, see “Avoiding jams” on page 1-16
. If jams do occur, follow the steps outlined in this section.
To resolve the paper jam messages, you must clear the entire paper path, and then touch Continue to clear the message and resume printing. The MFP prints a new copy of the page that jammed if Jam Recovery is set to On or Auto; however, the Auto setting does not guarantee the page will print.
Identifying jams
If the MFP jams, the appropriate jam message will be displayed on the touch screen Print status message bar.
Copy
Fax E-mail
FTP
Menus
Status/
Supplies
200.01 Paper jam, [x] pages jammed. Leave paper in bin.
See the diagram on
“Access doors and trays” on page 3-39 for an overview of the paper path and areas
where jams may occur. The path varies depending on the MFP paper sources.
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Access doors and trays
The following illustration shows the path that print media travels through the MFP. The path varies depending on the input source (trays, multipurpose feeder, envelope feeder) you are using.
The numbers in following the illustration indicate the numbers that can appear on the operator panel and designate the general area of a paper jam.
Models X644e/X646e shown
Doors and trays Path and locations
CAUTION
Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet drawer. Certain other configurations also must have a printer stand or printer base.
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Understanding jam messages
The following table lists the jam messages that can occur and the action necessary to clear the message. The jam message indicates the area where the jam occurred. However, it is best to clear the entire paper path to ensure you have cleared all possible jams.
Message
23x Paper Jam Open Duplex Rear
260 Paper Jam Check Env Feeder
290, 291, 292, and 294 Scanner
What to do*
Open the bottom then top front covers, remove the print cartridge, and then remove the jam.
Open the rear door on the MFP, and remove the jam.
Remove the duplex tray from the duplex unit, raise the duplex deflector, and remove the jam. Open the rear duplex door, and remove the jam.
Remove all media from the multipurpose feeder, flex and stack the media, reload the multipurpose feeder, and adjust the guide.
Lift the envelope weight, remove all envelopes, flex and stack the envelopes, reload the envelope feeder, and adjust the guide.
Remove all original documents from the ADF. Open the ADF cover, and remove any jammed pages. Open the document cover, and remove any jammed pages. Open the lower exit guide, and remove any jammed pages.
Clearing jams
Although there are several places a jam can occur, clearing the paper path is fairly easy. Paper jams can occur in three areas: the front of the MFP, inside the MFP, and at the rear of the MFP. Jams in the front of the MFP occur in the input options or the duplex tray. Jams inside the MFP occur in two locations and require the removal of the print cartridge. Jams can also occur at the rear of the MFP or duplex unit.
Note: The following clearing jam instructions may seem out of numerical sequence. However, they have been
.
250 Paper Jam Check MP Feeder
1.
Remove the paper from the multipurpose feeder.
2.
Flex, fan, and restack the media, and place it into the multipurpose feeder.
3.
Load the print media.
4.
Slide the side guide toward the inside of the tray until it lightly rests against the edge of the media.
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5.
Touch Continue .
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260 Paper Jam Check Env Feeder
The envelope feeder feeds envelopes from the bottom of the stack; the bottom envelope will be the one that is jammed.
1.
Lift the envelope weight.
2.
Remove all envelopes.
If the jammed envelope has entered the MFP and cannot be pulled out, remove the envelope feeder.
a.
Lift the envelope feeder out of the MFP, and then set it aside.
b.
Remove the envelope from the MFP.
Note: If you cannot remove the envelope, the print cartridge will have to be removed. See
Paper Jam Remove Cartridge” on page 3-46 for more information.
c.
Reinstall the envelope feeder. Make sure it snaps into place.
3.
Flex and stack the envelopes.
1
2
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4.
Load the envelope feeder.
5.
Adjust the guide.
6.
Lower the envelope weight.
7.
Touch Continue .
1
2
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23x and 24x jams
Paper jams in these areas can occur on the incline surface of a tray or across more than one tray. To clear these areas:
1.
Open the MFP paper tray, and remove any jammed media.
2.
Open the duplex tray.
To remove the media, pull up.
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3.
Open any optional trays beginning at the top, and remove any jammed media.
Pull the print media either up or down. If it does not pull easily one way, try the other way.
CAUTION
Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet drawer. Certain other configurations also must have a printer stand or printer base. More information is available on our Lexmark
Web site at www.lexmark.com/multifunctionprinters .
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4.
If you have an optional 2000-sheet feeder, open the front door, press the elevator button to lower the tray, remove the jam, and make sure the stack of print media is neat and aligned.
5.
Touch Continue .
CAUTION
Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet drawer. Certain other configurations also must have a printer stand or printer base. More information is available on our Lexmark
Web site at www.lexmark.com/multifunctionprinters .
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200 and 201 Paper Jam Remove Cartridge
1.
Push the release latch, and lower the multipurpose feeder.
2.
Push the release latch, and open the top front cover.
CAUTION
The inside of the MFP may be hot. Allow the MFP to cool before touching any internal components.
3.
Lift and pull the print cartridge out of the MFP.
Warning: Do not touch the photoconductor drum on the underside of the cartridge. Use the cartridge handle whenever you are holding the cartridge.
4.
Place the print cartridge aside.
Note: Do not leave the cartridge exposed to light for extended periods.
2
1
Note: The print media may be covered with unfused toner, which can stain garments and skin.
5.
Pull the print media up and toward you.
CAUTION
Do not use any pointed objects to remove the paper. This could cause personal injury or damage to the MFP.
Warning: If the print media does not move immediately when you pull, stop pulling. You need to access the print media from the MFP rear door.
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6.
Align and reinstall the toner cartridge.
7.
Close the top front cover.
8.
Close the multipurpose feeder.
9.
Touch Continue .
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1
2
202 Paper Jam Open Rear Door
1.
If the paper is exiting the MFP, pull the media straight out, and then touch Continue . Otherwise, continue with step 2.
2.
Open the MFP rear door.
CAUTION
The inside of the MFP may be hot. Allow the MFP to cool before touching any internal components.
CAUTION
Do not use any pointed objects to remove the paper. This could cause personal injury or damage to the MFP.
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3.
Remove the jammed media.
4.
Close the rear door.
5.
Touch Continue .
23x Paper Jam Open Duplex Rear Door
1.
Open the duplex rear door.
2.
Remove the jammed media.
Depending on the media location, pull the media either up or down.
3.
Close the duplex rear door. Make sure it snaps into place.
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4.
Touch Continue .
Clearing ADF jams
290, 291, 292, and 294 Scanner Jams
1.
Remove all original documents from the ADF.
2.
Open the ADF top cover, and remove any jammed pages.
3.
Open the ADF cover, and remove any jammed pages.
7
4
1
2
5
8
9
6
3
0
#
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4.
Open the lower entrance guide, and remove any jammed pages.
5.
Close the lower exit guide.
6.
Close the ADF cover.
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4. Repair information
Warning: Read the following before handling electronic parts.
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Handling ESD-sensitive parts
Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards:
• Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until you are ready to install the part into the machine.
• Make the least-possible movements with your body to prevent an increase of static electricity from clothing fibers, carpets, and furniture.
• Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges any static electricity in your body to the machine.
• Hold the ESD-sensitive part by its edge connector shroud (cover); do not touch its pins. If you are removing a pluggable module, use the correct tool.
• Do not place the ESD-sensitive part on the machine cover or on a metal table; if you need to put down the
ESD-sensitive part for any reason, first put it into its special bag.
•
Machine covers and metal tables are electrical grounds. They increase the risk of damage because they make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.)
• Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install machine covers when you are not working on the machine, and do not put unprotected ESD-sensitive parts on a table.
• If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case).
• Be extra careful in working with ESD-sensitive parts when cold-weather heating is used, because low humidity increases static electricity.
Repair information 4-1
7002-xxx
Adjustment procedures
Fuser solenoid adjustment
Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while installed in the MFP. Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature. The solenoid air gap for all models is
4.5 mm ± 0.1 mm.
Gap adjustment
The gap adjustment allows you to increase the minimum gap between sheets of paper as they are fed through the MFP. This adjustment reduces the MFP overall performance, such as pages per minute, but can help in reducing the amount of curl of some printed media, thus improving media stacking in the output bin.
1.
Enter the Diagnostic Menu.
2.
Select EP SETUP from the Diagnostic Menu.
3.
Select Gap Adjust .
4.
The range of the GAP adjustment is 0 to 255. Adjust the gap setting by using arrows to select the value and press Submit . If GAP=0 displays, it indicates a factory setting to minimum gap. Select a value, and run several copies of the media that displays a curl problem. It may take several tries before improvement is noticed.
Note: This setting has no effect when duplexing.
Printhead assembly adjustment—printer
Do the printhead assembly adjustment whenever you remove or replace the printhead assembly or loosen the mounting screws.
Install the new printhead with the three mounting screws centered in the slots in the printhead frame assembly.
Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots. It is necessary to perform a registration adjustment before locking down the three printhead mounting screws.
To perform the registration adjustment:
1.
Turn off the MFP.
2.
Press and hold the 3 and 6 buttons simultaneously, and turn on the MFP.
3.
Release the buttons after 10 seconds.
4.
Select Registration from the menu.
5.
Select Quick Test Page . The test page should only be printed on letter or A4 paper from Tray 1. The
Quick Test Page consists of alignment diamonds, horizontal lines that can be used for skew adjustment, page count setting, MFP serial number code levels, and print registration settings.
6.
Check the Quick Test Page for any sign of skew by checking the diamonds at the top left and top right of the test page for equal distance from the top of the page. If necessary, adjust the left or right printhead mounting screws, and check the skew again by running another Quick Test Page. This procedure may take two or three attempts before you get satisfactory results.
7.
When you have the correct adjustment, gently tighten the printhead mounting screws, being careful not to move the printhead assembly.
4-2 Service Manual
7002-xxx
Paper alignment assembly adjustment
Do the alignment assembly adjustment whenever you replace the alignment assembly. Always print a copy of the
Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw. When replacing the alignment assembly, it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one.
• If you are replacing the alignment assembly, go to step A.
• If you are only adjusting the reference adjustment screw, go to step B.
Step A
Print a copy of the Quick Test Page, and check the margin adjustments printed on the test page. These settings
should be within the range specified in “Registration (printer)” on page 3-5
.
Do the reference adjustment if you are sure the margins are set correctly.
1.
Loosen the locknut on the inside rear of the alignment assembly.
2.
Remove the two screws holding the alignment assembly to the left side frame.
3.
Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from the MFP. It is not necessary to completely remove the screw.
4.
Install the new alignment assembly. Turn the reference screw clockwise with a 7 mm nut driver or M3 Allen wrench until it touches the back of the reference plate, and tighten the nut with a 5.5 mm wrench.
The reference adjustment screw can be adjusted without loosening the nut. Turn the screw clockwise a few turns, and print a copy of the Quick Test Page as you check the diamonds on the left margin. Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want.
Step B
Print a copy of the Quick Test Page, and check the margin adjustments printed on the test page. These settings
should be within the range specified in “Registration (printer)” on page 3-5
. The reference screw can be adjusted without loosening the locknut. Turn the screw a few turns, and print a copy of the Quick Test Page as you check the diamonds on the left margin. Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want.
Repair information 4-3
7002-xxx
Scanner registration
Perform the Automatic Scanner Registration when:
• The ADF assembly, CCD, RIP card or SCU card is replaced.
• NVRAM is reset.
• The operator panel is replaced.
Automatic Scanner Registration
Note: Before performing scanner registration, ensure MFP registration and alignment is properly set. See
“Registration (printer)” on page 3-5
and “Printhead assembly adjustment—printer” on page 4-2 for more
information.
Note: Always store the colored sheets so they do not become creased or torn.
To perform the Automatic Scanner Registration:
1.
Enter the Configuration menu: a.
Turn off the printer.
b.
Press and hold the 2 and 6 buttons simultaneously.
c.
Turn on the printer.
d.
Release the buttons after 10 seconds.
2.
Scroll through the menus using the down arrow, and select Automatic Scanner Registration from the
Configuration menu.
Please place a piece of dark colored paper on the Flatbed and in the ADF
Start
Back
3.
Place a colored piece of paper in the ADF, making sure the edge guides are properly adjusted. Place another piece of paper (A4 or letter) on the flatbed.
Note: Use a light blue sheet of paper for the ADF registration. The best results were obtained using
Cascade MP Colors Blue 20 lb. paper (Boise Cascade part P1-MP-2201-BE). A moderate density blue paper should work if this paper cannot be found.
4-4 Service Manual
7002-xxx
4.
Touch Start .
The touchscreen displays
DO NOT POWER OFF Scanner Registration.
When complete, a screen similar to the following appears:
Scanner registration successfully completed
Continue
5.
Touch Continue .
Note: After the registration test is complete, success or failure is indicated on the touchscreen.
Note: If the Automatic Scanner Registration displays a failure, repeat the process making sure the paper is aligned as correctly as possible. If the process fails again, contact the next level of support.
6.
Verify the results by running a copy of a quick test page created during MFP registration. See “Print tests” on page 3-6 for more information.
Manual registration
Note: Manual registration should be performed only after automatic registration is performed. The primary purpose of manual registration is to fine-tune the automatic adjustments already made. Contact your next level of support for assistance in performing the Manual Scanner Registration.
Repair information 4-5
7002-xxx
Removal procedures
CAUTION
Remove the power cord from the MFP or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the MFP.
CAUTION
Use the handholds on the side of the MFP. Make sure your fingers are not under the MFP when you lift or set the MFP down.
Note: Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.
Scanner ADF and flatbed removals
ADF front cover removal
1.
Open the ADF top cover.
2.
Remove the two screws (A).
A
3.
Release the ADF front cover latch (B) on the right side under the scanner, and then release the latch (B) on the left side.
4-6 Service Manual
ADF pick assembly removal
1.
Grasp the pick assembly, and gently push the shaft to the right to free the left side.
7002-xxx
ADF rear cover removal
1.
Remove the two screws (A).
A
Repair information 4-7
7002-xxx
2.
Remove the screw (B) on the right side.
3.
Remove the cable blocks (C) from the square notches. For models X644e/X642e, there are two cables and notches and for model X642e, there is a single cable.
Model X644e/X646e Model X642e
Replacement note: When replacing the ADF rear cover, be sure to align the cables (C) in the notches and press the square portions of the cables into the holes.
4-8 Service Manual
ADF top cover removal
1.
Remove the ADF front cover. See
“ADF front cover removal” on page 4-6 .
2.
Remove the ADF rear cover. See
“ADF rear cover removal” on page 4-7
.
3.
Open the ADF top cover.
4.
Remove the shoulder screw (A) on the front.
7002-xxx
A
5.
Remove the shoulder screw (B) on the rear with a long shank screwdriver. Models X644e/X646e shown.
6.
Remove the ADF top cover.
Repair information 4-9
7002-xxx
Scanner left side cover removal
1.
Remove the two screws (A).
A
2.
Slide the cover toward the rear to unlatch the cover, and remove.
Note: Model X644e/X646e shown.
4-10 Service Manual
Front flatbed cover removal
Pull the top of the cover out first, and lift away to remove.
7002-xxx
Scan cover (flatbed) removal
1.
Remove the glass holder assembly. See
“Scanner flatbed glass holder assembly removal” on page 4-50
.
2.
Remove the flatbed contact glass. See
“Flatbed contact glass removal” on page 4-31 .
3.
Remove the three screws (A).
A
Repair information 4-11
7002-xxx
4.
Lift the scan cover (flatbed). Scanner right side cover removal
Scanner right side cover removal
1.
Remove the screw (A).
A
4-12 Service Manual
2.
Slide cover back to release tab (B).
B
ADF attach screws removal
1.
Open the document cover.
2.
Remove the two ADF attach screws (A) by turning them by hand.
7002-xxx
A
Note: Do not remove the screws toward the rear.
Repair information 4-13
7002-xxx
ADF CCD module assembly removal (models X644e/X646e)
1.
Remove the ADF assembly. See
“ADF complete assembly removal” on page 4-15
.
2.
Remove the ADF front cover. See
“ADF front cover removal” on page 4-6 .
3.
Remove the flatbed white cushion. See
“Flatbed white cushion removal” on page 4-32
.
4.
Turn the ADF assembly upside down, carefully supporting the unit.
5.
Open the lower exit guide assembly.
6.
Remove the four screws (A) and the two small screws (B) securing the ADF CCD module assembly.
B A B
7.
Remove the ADF jam tray sensor (C) from the mounting bracket to protect it from being bumped or damaged during removal of the ADF CCD module assembly.
8.
Remove the ADF CCD module assembly, and disconnect the ADF CCD to scan control cable (D).
C D
Reinstallation notes :
• Be sure to avoid touching the glass of the new FRU during installation.
• Be sure to reinstall the ADF jam tray sensor.
4-14 Service Manual
ADF complete assembly removal
1.
Twist the thumbscrews to disconnect the cable(s) (A) at the back of the ADF assembly.
Note: Model X642e has a single cable.
Models X644e/X646e Model X642e
7002-xxx
A A
2.
Remove the ADF attach screws. See
“ADF attach screws removal” on page 4-13 .
Note: Do not remove the two screws in the back.
3.
Lift the ADF up, and make sure you clear the two rear screws. The hinge is slotted to allow the ADF to come off and leave the screws in place.
Note: Whenever the complete ADF assembly is replaced, it is necessary to perform the scanner registration.
See
“Scanner registration” on page 4-4 .
Repair information 4-15
7002-xxx
ADF upper entrance guide assembly removal
1.
Remove the ADF pick assembly. See
“ADF pick assembly removal” on page 4-7
.
2.
Remove the document tray assembly. See
“Document tray assembly removal” on page 4-23 .
3.
Remove the three screws (A).
4.
Lift the cover.
Replacement note: Be sure to align the tabs.
A
4-16 Service Manual
7002-xxx
CCD belt removal
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the flatbed contact glass. See
“Flatbed contact glass removal” on page 4-31
3.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
4.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
5.
Push the CCD belt tension spring to take tension from the belt.
6.
Unhook the belt from the motor shaft.
Repair information 4-17
7002-xxx
7.
Push the flatbed CCD all the way to the left.
8.
Unhook the main CCD guide shafts (E) from the holes in the right side. This allows you to remove the flatbed CCD module from the shafts.
E
9.
Carefully lay the flatbed CCD module on the scan frame, being careful not to touch the card, lamp, or mirrors.
10.
Disconnect the CCD belt from the retainer (F) in the flatbed CCD module assembly.
11.
Remove the CCD belt.
F
4-18 Service Manual
7002-xxx
CCD belt tension spring removal
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the flatbed contact glass. See
“Flatbed contact glass removal” on page 4-31 .
3.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
4.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
5.
Push the CCD belt tension spring toward the motor to take tension from the belt.
6.
Unhook the belt from the motor shaft.
Repair information 4-19
7002-xxx
7.
Unhook the main CCD guide shaft (A) from the hole in the right side, and slide it out of the way. This allows you to access the spring.
A
8.
Remove the CCD belt tension spring (A).
B
4-20 Service Manual
7002-xxx
Cover closing actuator removal
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
3.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
4.
With pliers, pull firmly to remove the actuator (A).
A
Repair information 4-21
7002-xxx
Cover closed actuator removal
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
3.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
4.
With pliers, pull firmly to remove the actuator (A).
A
4-22 Service Manual
Document tray assembly removal
1.
Remove the ADF front cover. See
“ADF front cover removal” on page 4-6 .
2.
Remove the ADF rear cover. See
“ADF rear cover removal” on page 4-7
.
3.
Remove the two screws (A).
7002-xxx
4.
For modelsX644e/X646e, disconnect the connector (B).
Models X644e/X646e
B
Repair information 4-23
7002-xxx
Flatbed CCD ribbon cable removal
Illustrations represent models X644e/X646e. Unless there is an indication, the procedure is the same. Differences are shown side by side.
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the flatbed contact glass. See
“Flatbed contact glass removal” on page 4-31 .
3.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
4.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
5.
Push the flatbed CCD toward the motor to take tension from the belt.
6.
Unhook the belt from the motor shaft.
7.
Push the flatbed CCD all the way to the left.
4-24 Service Manual
7002-xxx
8.
Unhook the main CCD guide shafts (A) from the holes in the right side. This allows you to remove the flatbed CCD module from the shafts.
9.
Carefully lay the flatbed CCD module on the scan frame, being careful not to touch the card, lamp, or mirrors.
10.
Disconnect the flatbed CCD ribbon cable (B) from the flatbed CCD module.
Repair information 4-25
7002-xxx
11.
Remove the screw (C) from the flatbed CCD ribbon cable clamp.
12.
Remove the printer left side cover. See
“Printer left side cover removal” on page 4-56 .
13.
Remove the seven screws (D) from the SCC and HDD shield. (Models X644e/X646e shown)
4-26 Service Manual
7002-xxx
14.
Loosen the screws for the printer outer shield, and slide shield to the left to allow enough room to remove the scanner control card shield and the hard disk shields.
15.
Disconnect the flatbed CCD ribbon cable from the scanner control card (E).
Models X644e/X646e (X646e shown) Model X642e
E
16.
Remove the toroid from the cable, and set aside for reinstallation.
17.
Disconnect the flatbed CCD ribbon cable from the IF interface card.
E
Repair information 4-27
7002-xxx
Flatbed CCD module assembly removal
Illustrations represent models X644e/X646e. Unless there is an indication, the procedure is the same. Differences are shown side by side.
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the flatbed contact glass. See
“Flatbed contact glass removal” on page 4-31 .
3.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
4.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
5.
Push the CCD belt tension spring to take tension from the belt.
6.
Unhook the belt from the motor shaft.
4-28 Service Manual
7002-xxx
7.
Push the flatbed CCD all the way to the left. There is a slot in the frame to allow the flatbed CCD module assembly to be lifted out.
8.
Unhook the main CCD guide shafts (E) from the holes in the right side. This allows you to remove the flatbed CCD module assembly from the shafts.
A
Repair information 4-29
7002-xxx
9.
Disconnect the flatbed CCD ribbon cable (B) from the flatbed CCD module.
10.
Disconnect the CCD belt from the retainer (C) in the flatbed CCD module assembly
C
11.
Remove the flatbed CCD module assembly.
4-30 Service Manual
7002-xxx
Flatbed contact glass removal
1.
Open the document cover.
2.
Remove the scanner flatbed glass holder assembly. See
“Scanner flatbed glass holder assembly removal” on page 4-50 .
3.
Remove the upper glass holder. See
“Upper glass holder removal” on page 4-53 .
4.
Slide the glass to the left, and lift it.
CAUTION
While the glass edge is beveled, handle it carefully to avoid cutting your hand.
5.
Lift the glass, and place it on a clean, dry cloth.
Repair information 4-31
7002-xxx
Flatbed white cushion removal
1.
Open the document cover.
2.
Peel the Velcro attached pad from one corner.
To replace the flatbed white cushion, place the cushion on the document glass, and close the document cover.
4-32 Service Manual
7002-xxx
Flatbed interconnect card removal
Warning: When replacing any one of the following components:
• Flatbed Interconnect card (ICC)
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
Warning:
Illustrations represent models X644e/X646e. Unless there is an indication, the procedure is the same. Differences are shown side by side.
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the flatbed contact glass. See
“Flatbed contact glass removal” on page 4-31 .
3.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
4.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
5.
Remove the three screws (A) that attach the hinge support bracket to the rear scan bracket.
A
6.
Remove the two screws (B) from the top.
7.
Remove the two screws (C) from the left side and right side.
Repair information 4-33
7002-xxx
8.
Remove the two screws (D) from the left bottom and right bottom.
D
C B C
9.
Disconnect all connectors (E). There are either four or three, depending on model.
10.
Remove the four screws (F).
Models X644e/X646e Model X642e
D
E E
F F
11.
Remove the card.
4-34 Service Manual
7002-xxx
Flatbed paper length sensor assembly removal
Illustrations represent models X644e/X646e. Unless there is an indication, the procedure is the same. Differences are shown side by side.
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the flatbed contact glass. See
“Flatbed contact glass removal” on page 4-31 .
3.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
4.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
5.
Remove the three screws (A) that attach the hinge support bracket to the rear scan bracket.
A
Repair information 4-35
7002-xxx
6.
Remove the two screws (B) from the top.
7.
Remove the two screws (C) from the left side and right side.
8.
Remove the two screws (D) from the left bottom and right bottom.
Note: Some models may look different. Model X646e is shown.
D
C B
9.
Remove the two screws (E) from the sensor assembly cover.
Models X644e/X646e
C
Model X642e
D
E E
4-36 Service Manual
10.
Turn over the sensor cover, and remove the screw (F) for the sensor you need to replace.
Note: There are three sensors in models X644e/X646e. There is only one in model X642e.
11.
Disconnect the sensor cable (G) at the sensor and remove the sensor.
Note: Only remove one sensor at a time to make it easier to reinstall the right cable.
Models X644e/X646e Model X642e
7002-xxx
G F G F
Repair information 4-37
7002-xxx
Flatbed scan assembly removal
Illustrations represent models X644e/X646e. Unless there is an indication, the procedure is the same. Differences are shown side by side.
1.
Remove the ADF assembly. See
“ADF complete assembly removal” on page 4-15
.
2.
Remove the printer left side cover. See
“Printer left side cover removal” on page 4-56 .
3.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
4.
Remove the seven screws (A) from the SCC and HDD shield.
5.
Loosen the screws for the printer outer shield and slide shield to the left to allow enough room to remove the scanner control card shield and the hard disk shield.
4-38 Service Manual
6.
Disconnect the two cables (B).
Models X644e/X646e (X646e shown) Model X642e
7002-xxx
B B
7.
Remove the two screws (C) from the left side.
8.
Remove the two screws (D) that attaches the ground bracket to the SCC/HDD shield.
Note: The ground bracket is only on models X644e and X646e.
Model X646e shown
Repair information 4-39
7002-xxx
9.
Remove the scanner right side cover. “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
10.
Remove the two screws from the right side (E).
E
11.
Pull the scan unit forward to unhook the unit from the printer, and lift the scan unit from the printer.
Installation note:
Remove any clear protective covers from the scanner registration strip and the flatbed white cushion after installation.
4-40 Service Manual
7002-xxx
Flatbed scan motor assembly removal
Illustrations represent models X644e/X646e. Unless there is an indication, the procedure is the same. Differences are shown side by side.
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the flatbed contact glass. See
“Flatbed contact glass removal” on page 4-31 .
3.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
4.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
5.
Remove the three screws (A) that attach the hinge support bracket to the rear scan bracket.
A
6.
Remove the two screws (B) from the top.
7.
Remove the two screws (C) from the left side and right side.
Repair information 4-41
7002-xxx
8.
Remove the two screws (D) from the left bottom and right bottom.
D
C B C
9.
Push the flatbed CCD toward the motor to take tension from the CCD belt.
10.
Unhook the CCD belt from the motor shaft.
D
11.
Carefully lay the flatbed CCD module on the scan frame, being careful not to touch the card, lamp, or mirrors.
4-42 Service Manual
12.
Remove the three screws (E) that attach the FB scan motor assembly to the frame.
7002-xxx
E
13.
Remove the flatbed scan motor assembly.
Repair information 4-43
7002-xxx
Hard disk removal
Note: This procedure applies to model X646e only.
1.
Remove the printer left side cover. See
“Printer left side cover removal” on page 4-56 .
2.
Remove the six screws (A) from the SCC and HDD shield.
3.
Loosen the screws for the printer outer shield, and slide the shield to the left to allow enough room to remove the scanner control card shield and the hard disk shield.
4.
Disconnect the two cables (B).
4-44 Service Manual
5.
Remove the four screws (C).
6.
Remove the hard disk.
7002-xxx
Repair information 4-45
7002-xxx
Home sensor removal
1.
Remove the scan cover (flatbed). See “Scan cover (flatbed) removal” on page 4-11
.
2.
Remove the flatbed contact glass. See
“Flatbed contact glass removal” on page 4-31 .
3.
Remove the scanner right side cover. See “Lift the scan cover (flatbed). Scanner right side cover removal” on page 4-12 .
4.
Remove the scanner left side cover. See
“Scanner left side cover removal” on page 4-10 .
5.
Remove the screw (A).
6.
Remove the sensor and bracket (B).
7.
Disconnect the cable (C) from the sensor.
8.
Unclip the home sensor (D) from the bracket.
4-46 Service Manual
7002-xxx
Lower exit guide assembly removal
Illustrations represent models X644e/X646e. Unless there is an indication, the procedure is the same. Differences are shown side by side.
1.
Remove the ADF front cover. See
“ADF front cover removal” on page 4-6 .
2.
Remove the flatbed white cushion. See
“Flatbed white cushion removal” on page 4-32
.
3.
Open the document cover.
4.
Press the latch (A) to open the lower exit guide assembly.
5.
Remove the two screws (B), and remove the metal plate (C). Set the plate aside.
A
6.
Remove the screw (D) on the ADF frame.
B
E D
7.
Remove the lower exit guide assembly.
Installation note: Be sure to route the cable through the hole (E) in the front ADF frame.
Repair information 4-47
7002-xxx
Pickup solenoid assembly removal
1.
Remove the two screws (A).
2.
Unhook the spring (B).
Note: Two springs attach to the same post. The other spring should be hooked on first, and spring (B) should be attached on the outside or in front of the other spring.
3.
Remove the cable from the cable guide.
4.
Disconnect the connector (C), and remove the pickup solenoid assembly.
Scanner control card removal
Illustrations represent models X644e/X646e. Unless there is an indication, the procedure is the same. Differences are shown side by side.
1.
Remove the printer left side cover. See
“Printer left side cover removal” on page 4-56 .
2.
Remove the six screws (A) from the SCC and HDD shield.
4-48 Service Manual
7002-xxx
3.
Loosen the screws for the printer outer shield, and slide the shield to the left to allow enough room to remove the scanner control card shield and the hard disk shield.
4.
Disconnect all the cables (B).
Models X644e/X646e (X646e shown) Model X642e
5.
Remove the four screws (B).
6.
Tilt the card to remove the scanner control card.
Repair information 4-49
7002-xxx
Scanner flatbed glass holder assembly removal
1.
Open the document cover.
2.
Remove the two screws (A).
A
3.
Carefully pry up the inner edge.
Warning: Do not use tools that can scratch the glass.
Warning: Be careful not to touch the calibration strip (A) on the underside of the scanner flatbed glass holder.
4-50 Service Manual
7002-xxx
4.
Lift to release the three tabs (C).
Warning: Place the scanner flatbed glass holder assembly on a clean, dry cloth to protect the glass from scratches.
Warning: Do not touch the calibration strip (D.)
Repair information 4-51
7002-xxx
Separator assembly torque limiter removal
1.
Open the ADF top cover.
2.
Remove the ADF pick arm assembly. See
“Document tray assembly removal” on page 4-23 .
3.
Unsnap and remove the paper guide (A).
A
4.
Remove the clip (B).
5.
Remove the reverse roller (C).
6.
Slide the separator assembly torque limiter (D) off the shaft.
4-52 Service Manual
D C B
Upper glass holder removal
1.
Open the document cover.
2.
Slide the upper glass holder to the left to unlatch.
7002-xxx
3.
Lift the upper glass holder to remove.
Repair information 4-53
7002-xxx
Printer removals
CAUTION
Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer.
CAUTION
Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
Note: Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.
Fuser wiper cover assembly removal
1.
Squeeze the two latches together, and pull up.
2.
Remove the fuser wiper cover assembly.
3.
Remove the fuser wiper cover assembly.
4-54 Service Manual
Upper sub cover removal
1.
Remove flatbed scanner assembly. See
“Flatbed scan assembly removal” on page 4-38 .
2.
Remove screw (A) from right side frame holding upper sub cover.
7002-xxx
3.
Pull up on the right side of the upper sub cover.
4.
Remove the upper sub cover.
Repair information 4-55
7002-xxx
Upper tray cover removal (paper support)
1.
Remove the flatbed scan assembly. See
“Flatbed scan assembly removal” on page 4-38 .
2.
Raise the upper tray cover, and lift to release the latches.
3.
Remove the upper tray cover.
Printer left side cover removal
1.
Open the upper and lower front covers.
2.
Press the two left door latch buttons (A), and open the left door.
4-56 Service Manual
3.
Release the top hinge from the latch (B).
7002-xxx
4.
Lift the door to release the bottom from the pin (B), and remove the door.
Repair information 4-57
7002-xxx
Redrive door
1.
With the redrive door partially open, lift and free the left side.
2.
Remove the redrive door.
Printer right cover removal
1.
Remove the upper sub cover. See
“Upper sub cover removal” on page 4-55 .
2.
Open the upper and lower front covers.
3.
Remove the print cartridge.
4.
Remove the right front cover mounting screw (A).
4-58 Service Manual
5.
Remove the redrive door. See
6.
Remove the right rear cover mounting screw (C).
7002-xxx
C
7.
Remove the two redrive screws (D).
8.
Press the two latches to remove the redrive assembly.
Repair information 4-59
7002-xxx
9.
Press the latch (D) firmly to release the front of the right cover.
D
10.
Pull up and out on the right cover to release the three cover retainers (E) at the bottom.
E
Note: When replacing the right side cover, make sure the three cover retainers (E) are correctly located in the appropriate slots in the right side frame.
4-60 Service Manual
Operator panel left cover assembly removal
Illustrations represent models X644e/X646e. Unless there is an indication, the procedure is the same.
1.
Remove the printer left side cover. See
“Printer left side cover removal” on page 4-56 .
2.
Open the printer upper front cover.
3.
Remove the two screws (A).
Note: Model X644e shown.
7002-xxx
4.
For model X642e, disconnect the cable (B).
Model X642e
Repair information 4-61
7002-xxx
5.
For model X642e, remove the screw (C) that attaches the ground cable.
6.
Remove the operator panel left cover assembly.
4-62 Service Manual
7002-xxx
Installation note: Be sure the latches (C) on the back of the operator panel left cover are fastened into the upper front cover hinge slots.
Repair information 4-63
7002-xxx
Operator panel right cover assembly removal
1.
Open the printer upper front cover.
2.
Remove the two screws (A).
A
3.
Lift the operator panel right cover assembly carefully to access the cables.
Warning: Be careful not to tear or break the small ribbon cable from its connector (B).
4.
Disconnect the four cables (C) from the UI control card.
C B
5.
Remove the operator panel right cover assembly.
C
4-64 Service Manual
7002-xxx
Installation note: Be sure the latches (D) on the top of the operator panel right cover are fastened into the upper front cover hinge slots.
Repair information 4-65
7002-xxx
Touchscreen bezel removal
1.
Open the printer upper front cover.
2.
Use a small screwdriver or other small tool to carefully release the two tabs (A) under the touchscreen bezel.
Warning: Be careful not to scratch or mar the touchscreen bezel.
Models X644e/X646e Model X642e
A
3.
For model X642e, disconnect the UICC#3 cable (B).
A
4.
Remove the touchscreen bezel.
4-66 Service Manual
B
7002-xxx
LCD touchscreen removal—models X644e and X646e
CAUTION
When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
1.
Remove the operator panel left front cover. See
“Operator panel left cover assembly removal” on page 4-61
.
2.
Remove the two screws (A) on the operator panel right front cover.
A
3.
Lift the operator panel right cover assembly carefully to access the cables.
Warning: Be careful not to tear or break the small ribbon cable from its connector (B).
4.
Disconnect the cables (C) from the UI control card.
C
Repair information 4-67
7002-xxx
5.
Remove the operator panel left side cover. See
“Operator panel left cover assembly removal” on page 4-61
.
6.
Disconnect the cable (D) from the LCD inverter card assembly.
D
7.
Remove the touchscreen bezel. See
“Touchscreen bezel removal” on page 4-66 .
8.
Press the two tabs (E) that limit range of motion, and rotate the LCD touchscreen up until it disconnects.
9.
Set the LCD touchscreen aside.
Warning: Avoid touching or placing pressure on the touchscreen. Do not handle roughly or drop.
4-68 Service Manual
7002-xxx
10.
Disconnect the ground cable. You might want to use a pair of pliers and a small flat blade screwdriver.
LCD touchscreen removal—model X642e
1.
Remove the bezel. See
“Touchscreen bezel removal” on page 4-66 .
2.
Remove the two screws (A) from the right side cover.
A
Repair information 4-69
7002-xxx
3.
Lift the operator panel right cover assembly carefully to access the cables.
Warning: Be careful not to tear or break the small ribbon cable (B) from its connector.
4.
Disconnect the cables (C) from the UI CC#.
B C
5.
Remove the operator panel left side cover. See
“Operator panel left cover assembly removal” on page 4-61
.
6.
Use a screwdriver to lift the lock and disconnect the cable (D) from the LCD inverter card assembly.
D
4-70 Service Manual
7002-xxx
7.
Press the two tabs (E) that limit range of motion, and rotate the LCD touchscreen up until it disconnects.
E E
Multipurpose feeder/lower front cover assembly removal
1.
Open the multipurpose tray to a position that allows the left and right tray hinge slots (A) to align with the
D-shape mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts.
Warning: Be careful not to break or stress the hinges.
2.
Remove the multipurpose tray/lower front cover assembly.
Repair information 4-71
7002-xxx
Left cover handle holder removal
1.
Open the left side cover.
2.
Remove the outer system board shield. See “Printer outer shield removal” on page 4-126
.
3.
Remove the two screws (A) holding the top of the left handle holder in place.
4.
Use the tab (B) to lift out the left handle holder.
Right cover handle holder removal
1.
Remove the right side cover. See
“Printer right cover removal” on page 4-58
.
2.
Remove the two screws (A) holding the top of the right handle holder in place.
3.
Lift out the right handle holder.
4-72 Service Manual
Left and right frame extensions
1.
Remove the ADF and flatbed scanner assemblies. See
“Flatbed scan assembly removal” on page 4-38
.
2.
Remove the toner cartridge.
3.
Turn the printer on its back.
4.
Remove the two screws (A) holding the right frame extension.
5.
Remove the two screws (B) securing the left frame extension.
7002-xxx
Repair information 4-73
7002-xxx
Pass thru plate
1.
Remove the redrive assembly. See
“Redrive assembly removal” on page 4-128 .
2.
Remove the screw (A) securing the pass thru plate.
3.
Carefully remove the plate until it is loose.
4.
Remove the fuser to system board DC cable (B) secured through the plate.
Note: Note the routing of the fuser card to system board DC cable.
4-74 Service Manual
Bevel gear removal
1.
Open the left door.
2.
Remove the inner shield.
3.
Remove the gear guard.
4.
Remove the power takeoff shaft and spring (A) through the bottom of the printer.
7002-xxx
5.
Place your thumb on the top of the gear, and press firmly down and away.
Note: You need to exert firm pressure to snap the bevel gear out.
Repair information 4-75
7002-xxx
Installation
1.
Remove any washer that may be present (A) and discard.
2.
Lubricate areas (A) that engage the journal (B) with grease from the provided packet.
3.
Place the new washer (C) on the bevel gear shaft.
4.
Insert the bottom portion and press or pull into position.
Note: You should hear two distinct snaps . If you only hear one, the bevel gear is only partially engaged and you should continue to press until the second snap is heard. Very firm pressure is required.
CAUTION
Do not brace your hands below the bevel gear itself. When the gear doublesnaps into place, it may pinch your hand.
5.
Install the power takeoff shaft and spring.
6.
Install the gear guard.
7.
Install the inner shield.
4-76 Service Manual
7002-xxx
Developer drive assembly removal
1.
Remove the system board and inner shield. See
“System board and inner shield removal —models
.
2.
Remove the two short screws (A) and the one long screw (B) securing the developer drive assembly.
3.
Remove the developer drive assembly.
4.
Remove the developer drive coupler kit. See
“Developer drive coupler kit removal” on page 4-78
.
Installation
1.
Place the developer coupler into the main motor drive shaft.
2.
Place the developer drive shaft on the developer drive.
3.
Align the developer drive shaft with the coupler.
4.
Be sure to replace the screws in the same positions.
Repair information 4-77
7002-xxx
Developer drive coupler kit removal
1.
Remove the developer drive. See
“Developer drive assembly removal” on page 4-77
.
2.
Remove the shaft drive and coupler.
ESD cover removal
1.
.
2.
Carefully lift the latch on the left (A), and remove the ESD cover.
Note: Be careful not to stress the hinge on the right (B).
4-78 Service Manual
Fuser assembly removal
CAUTION
Unplug the printer before you begin.
7002-xxx
1.
Remove the fuser wick assembly cover. See “Fuser wiper cover assembly removal” on page 4-54 .
2.
Remove the redrive assembly. See
“Redrive assembly removal” on page 4-128 .
3.
Remove the fuser mounting screws (A).
4.
Disconnect the fuser to LVPS AC cable (B) from the fuser lamp connector (C).
Repair information 4-79
7002-xxx
5.
Disconnect the fuser to system board DC cable (D) from the fuser board.
Note: Be sure to observe the routing of the LVPS to fuser lamp AC and the DC cable.
6.
Pull the cables free and remove the fuser.
Installation notes
1.
When you reinstall the fuser, be sure to route the fuser to LVPS AC cable (A) through the channel (B) on the right side frame above the LVPS, under the clip (C) over the LVPS, and through the notch in the frame (D).
2.
Route the fuser lamp cable through the opening in the fuser (E).
4-80 Service Manual
3.
Connect the fuser to LVPS AC cable to the fuser lamp connector (F) at the LVPS.
Note: Be sure to connect the fuser to system board DC cable after replacing the LVPS.
7002-xxx
Repair information 4-81
7002-xxx
Fuser exit sensor removal
1.
Remove the fuser. See
“Fuser assembly removal” on page 4-79 .
2.
Disconnect the fuser exit cable (A) from the fuser control board.
3.
Remove the screw (B) securing the cover containing the fuser exit sensor, flag, and spring.
4.
Release the two clips (C) holding the sensor in the bracket.
5.
Unplug the fuser exit sensor cable from the sensor.
Installation
1.
Move the fuser exit sensor flag out of the way to clip the sensor securely into the cover.
2.
Connect the fuser exit sensor cable.
4-82 Service Manual
7002-xxx
3.
Snap the bottom fastener of the sensor cover into place in the lower exit guide assembly, and use a small flat bladed screwdriver to ease the sensor cover into the clips.
4.
Replace the screw securing the sensor cover.
Note: Make sure the flag moves properly.
Fuser exit sensor flag and spring removal
1.
Remove the fuser exit sensor. See
“Fuser exit sensor removal” on page 4-82 .
2.
Note the position of the spring (A) in relation to the flag (B).
3.
Carefully ease the right arm (C) until the fuser exit sensor cover releases the flag and spring.
Repair information 4-83
7002-xxx
Spring replacement
1.
Place the spring on the left pin (A).
2.
Set the tang (B) on the flag.
4-84 Service Manual
7002-xxx
3.
Rotate the bent end (C) of the spring to add tension, place the pins between the sensor cover arms, and rest the bent end against the sensor cover frame.
Note: After replacing the sensor, flag, and spring, make sure the flag moves freely and returns.
Repair information 4-85
7002-xxx
Fuser lamp removal
CAUTION
The fuser and the fuser lamp may be hot. You may need to allow them to cool before handling them.
1.
Remove the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
2.
Disconnect the fuser lamp AC cable from the right side of the top cover assembly.
3.
Remove the two screws (A) from the right side fuser lamp contact cover.
Warning: Take care when removing the screw, as the lamp is under spring tension. When the contact is released, damage to the lamp or contact may occur.
4.
Remove the left lamp contact assembly.
A(202)
4-86 Service Manual
7002-xxx
5.
Remove the fuser lamp.
Warning: The lamp is under spring tension, and care must be used when removing the lamp from the fuser. Grip the lamp by the ceramic end piece, and remove it from the fuser assembly. Be careful not to touch the glass, as skin oils and acids can reduce the life of the lamp.
Use the following table to identify and install the correct lamp.
Description
Fuser Lamp 115 V
Fuser Lamp 220 V
P/N
Repair information 4-87
7002-xxx
Fuser narrow media sensor removal
1.
Remove the redrive assembly. See
“Redrive assembly removal” on page 4-128 .
2.
Remove the screw (A) securing the narrow media sensor cover to the fuser.
3.
With a thumbnail, release the catches (B) holding the sensor cover to the lower exit guide assembly (C) in place.
Note: You may need to move the narrow media flag out of the way to remove the sensor.
4.
Disconnect the fuser narrow media cable at the sensor.
5.
Release the catches holding the sensor in the cover.
Note: Hold the narrow media flag out of the way to remove the sensor from the cover.
4-88 Service Manual
Replacement
1.
Move the narrow media flag out of the way to clip the sensor securely into the cover.
7002-xxx
2.
Connect the fuser narrow media cable.
3.
Snap the bottom fastener of the sensor cover into place in the lower exit guide assembly, and rock the cover up until the top fastener snaps securely.
4.
Replace the screw securing the sensor cover.
Repair information 4-89
7002-xxx
Fuser narrow media flag and spring removal
1.
Remove the fuser narrow media sensor. See “Fuser narrow media sensor removal” on page 4-88
.
2.
Note the position of the spring (A) in relation to the flag (B).
3.
Carefully ease the right arm (C) of the sensor cover just far enough apart to release the flag and spring.
Spring replacement
1.
Place the spring on the left pin (A).
2.
Set the tang (B) on the flag.
4-90 Service Manual
7002-xxx
3.
Rotate the bent end (C) of the spring to add tension, place the pins between the sensor cover arms, and rest the bent end against the sensor cover frame.
A
Note: After replacing the sensor, flag, and spring, make sure the flag moves properly.
Repair information 4-91
7002-xxx
Fuser to LVPS AC cable removal
CAUTION
Unplug the printer before you begin.
1.
Remove the fuser wick assembly cover. See “Fuser wiper cover assembly removal” on page 4-54 .
2.
Remove the redrive assembly. See
“Redrive assembly removal” on page 4-128 .
3.
Remove the right side cover. See
“Printer right cover removal” on page 4-58
.
4.
Disconnect the fuser to LVPS AC cable (A) from the fuser lamp connector on the fuser, and remove the cable through the cable retainer (B) and the lower rectangular opening (C) in the fuser frame.
5.
Remove the pass thru plate. See “Pass thru plate” on page 4-74 .
6.
Disconnect the LVPS to system board DC cable (D) from the LVPS.
4-92 Service Manual
7002-xxx
7.
106
Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS
AC cable from the LVPS (E).
Note: The LVPS assembly may be difficult to remove from the printer. Do not use excessive force in the removal.
8.
Remove the fuser to LVPS AC cable.
Installation
1.
Plug in the fuser to LVPS AC cable (A) into the LVPS.
2.
Route the cable through the channel (B) on the right side frame above the LVPS, under the clip (C) over the LVPS, and through the notch in the frame (D).
Repair information 4-93
7002-xxx
3.
Route the cable through the lower rectangular opening (E).
4.
Connect the fuser to LVPS AC cable to the fuser lamp connector (F).
Note: Be sure to connect the fuser to system board DC cable after replacing the LVPS.
4-94 Service Manual
Fuser top cover removal
CAUTION
Unplug the printer before you begin.
7002-xxx
1.
Remove the fuser assembly. See
“Fuser assembly removal” on page 4-79 .
2.
Note the thermistor cable routing (A) and disconnect the thermistor cable at the fuser control board.
3.
Disconnect the AC fuser lamp cable (B) from the top right side of the fuser cover.
Repair information 4-95
7002-xxx
4.
Carefully remove the two screws (C) from the right side of the fuser lamp contact cover (D).
5.
Release the latch (E) and remove the cover.
6.
Remove the screw (F) on the left side and the screw (G) on the right side that attach the fuser upper cover assembly to the fuser frame.
7.
Remove screw (H) that attaches the side fuser lamp contact to the fuser top cover.
F
H
G
4-96 Service Manual
8.
Remove the fuser cover.
7002-xxx
Fuser transfer plate removal
1.
Remove the upper paper deflector. See
“Upper paper deflector assembly removal” on page 4-138 .
2.
Remove the transfer roll. See
“Transfer roll assembly removal” on page 4-132 .
3.
Remove the inner paper deflector. See
“Inner paper deflector assembly removal” on page 4-101
.
4.
Lift the left side of the fuser transfer plate (A), and move the plate to the left to clear the right side from its mounting.
5.
Remove the screw that attaches the transfer plate ground wire to the center pan.
6.
Remove the fuser transfer plate.
7.
Remove the screw that attaches the deflector cable to the transfer plate.
Repair information 4-97
7002-xxx
Gear release link removal
1.
Remove the system board and inner shield. See
“System board and inner shield removal —models
.
2.
Remove the developer drive.
3.
Disconnect the gear release link (A) from the hole in charge roll link (B).
Note: Lift the upper front cover to make it easier to remove the link.
4.
Rotate the link to disconnect the link from the main drive assembly.
5.
Remove the gear release link.
4-98 Service Manual
7002-xxx
High voltage power supply removal
CAUTION
There is a danger from hazardous voltage in the area of the product where you are working.
Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
1.
Remove the inner paper deflector. See
“Inner paper deflector assembly removal” on page 4-101
.
2.
Remove the right side cover. See
“Printer right cover removal” on page 4-58
.
3.
Disconnect the HVPS cable from the HVPS at connector (A).
A
4.
Disconnect the transfer roll cable (B) from the HVPS board.
Warning: Use care when disconnecting the cable from the transformer on the HVPS. The cable and connector can be easily damaged.
Repair information 4-99
7002-xxx
5.
Remove the HVPS mounting screws (C).
6.
Slide the HVPS to the left to release the mounting tab from the center pan, and remove the HVPS.
4-100 Service Manual
7002-xxx
Inner paper deflector assembly removal
1.
Remove the paper tray.
2.
Remove the upper paper deflector assembly. See
“Upper paper deflector assembly removal” on page 4-138
.
3.
Remove the MPF lower deflector assembly. See
“MPF lower paper deflector” on page 4-117 .
4.
Place the printer on its side.
5.
Gently pry the inner paper deflector from the left and right mounting posts (A) located on the bottom of the printer, and remove the deflector.
A
6.
Disengage the two latches (B) on the upper part of the deflector from the upper edge of the frame (C), and lift to remove.
C B C
Repair information 4-101
7002-xxx
Input sensor removal
1.
Remove the upper paper deflector.
“Upper paper deflector assembly removal” on page 4-138
.
2.
Loosen the MPF lower front cover. See
“Multipurpose feeder/lower front cover assembly removal” on page 4-71
.
3.
Remove the inner paper deflector.
“Inner paper deflector assembly removal” on page 4-101 .
4.
Disconnect the input sensor cable (A) from the input sensor (B).
5.
Release the input sensor from its mounting, and remove.
4-102 Service Manual
Integrated tray autocompensator assembly removal
1.
Remove the ADF scanner assembly. See
“ADF complete assembly removal” on page 4-15
.
2.
Remove the flatbed scanner assembly. See
“Flatbed scan assembly removal” on page 4-38 .
3.
Remove the paper tray.
4.
Remove the left door. See “Printer left side cover removal” on page 4-56
.
5.
Remove the outer shield. See
“Printer outer shield removal” on page 4-126 .
6.
Place the printer on its back.
7.
Disconnect the cannot motor cable (A) from the system board (J24).
7002-xxx
Repair information 4-103
7002-xxx
8.
Locate the integrated tray autocompensator assembly (B) on the bottom of the printer, and disconnect the autocompensator arm bias spring (C).
Note: When you remove the spring, note the larger loop attaches to the side frame.
9.
Remove the C-clip (D) that rests against the right side frame from the autocompensator pivot shaft.
10.
Disconnect the autocompensator sensor cable (E) from the assembly.
11.
Remove the autocompensator assembly mounting screw (F).
12.
Slide the shaft to the right, and push the shaft from the outside of the frame.
13.
Remove the integrated tray autocompensator assembly.
4-104 Service Manual
7002-xxx
Integrated tray autocompensator pick roll assembly removal
1.
Remove the integrated tray, and look underneath the printer for the autocompensator arm. Pull the arm down.
2.
Press on the end of the tab (A) and pull the pick roll off the arm. Repeat this step for the pick roll on the other side. Next, gently release the autocompensator arm. Discard the used pick rolls.
Repair information 4-105
7002-xxx
Installation
1.
Remove the new pick rolls from their packaging.
2.
Pull the autocompensator arm down. Locate the recessed area on the pick roll, and align it with the tab on the arm. There are two arrows on each pick roll. Make sure the bottom arrow faces you as you align the recessed area with the tab.
3.
Push the pick roll onto the arm with the tab aligned. Repeat this step on the other side to install the other pick roll.
4.
Gently release the autocompensator arm. Insert, integrated tray.
4-106 Service Manual
Interface card assembly removal
CAUTION
Unplug the printer before you begin.
7002-xxx
Warning: When replacing any one of the following components:
• Flatbed Interconnect card (ICC)
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
Warning:
Note: Any time the interface card assembly is replaced, the Configuration ID must be reset in NVRAM on the
new interface card. Go to “Configuration ID” on page 3-19
.
1.
Remove any feature or option cards from the interface card.
2.
Remove modem card (A) if installed.
3.
Remove the two screws securing the interface card (B).
4.
Remove the interface card assembly.
Repair information 4-107
7002-xxx
LCD inverter card assembly removal
1.
Remove the printer left side cover. See
“Printer left side cover removal” on page 4-56
.
2.
Remove the operator panel left side cover. See
“Operator panel left cover assembly removal” on page 4-61
.
3.
Remove the two cables (A).
4.
Remove the two screws (B).
Models X644e/X646e Model X642e
Note: For model X642e, you may need to carefully use a screw to disconnect the LCD display HV cable (C).
Model X642e
4-108 Service Manual
Low voltage power supply removal
CAUTION
Unplug the printer before you begin.
7002-xxx
1.
Remove the redrive assembly. See
“Redrive assembly removal” on page 4-128 .
2.
Remove the right side cover. See
“Printer right cover removal” on page 4-58
.
3.
Remove the pass thru plate. See “Pass thru plate” on page 4-74 .
4.
Remove the LVPS mounting screws (A) from the rear of the center pan.
5.
Disconnect the LVPS to system board cable.
The cable is difficult to disconnect. There are catches (B) that firmly hold latches on the LVPS card connector (C).
Repair information 4-109
7002-xxx
6.
Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS
AC lamp cable (D).
Warning: The LVPS assembly may be difficult to remove from the printer. Do not use excessive force in the removal.
7.
Remove the low voltage power supply.
4-110 Service Manual
Main fan removal
1.
Remove the ADF scanner assembly. See
“ADF complete assembly removal” on page 4-15
.
2.
Remove the flatbed scanner assembly. See
“Flatbed scan assembly removal” on page 4-38 .
3.
Remove the printer left side cover. See
“Printer left side cover removal” on page 4-56
4.
Open the left side cover.
5.
Remove the outer shield. See
“Printer outer shield removal” on page 4-126 .
6.
Remove the two screws (A) securing the upper plenum.
7002-xxx
7.
Remove the upper plenum.
Repair information 4-111
7002-xxx
8.
Clip the cable tie (B).
Note: Be careful not to damage any of the cables. Note the location of the cable tie for later replacement.
9.
Disconnect the main fan to the system board (C) at J4.
10.
Remove the main fan.
4-112 Service Manual
7002-xxx
Main drive assembly removal
1.
Remove the system board and inner shield. See
“System board and inner shield removal —models
.
2.
Remove the screw securing the gear guard (A).
3.
Remove the power take off shaft and spring. See
“Power takeoff shaft and spring removal” on page 4-126
.
4.
Remove the developer drive assembly. See
“Developer drive assembly removal” on page 4-77
.
5.
Lift and remove the cables from the cable hooks (B).
Repair information 4-113
7002-xxx
6.
Remove the ground cable screw (C).
7.
Remove the main drive assembly mounting screws (D).
8.
Disconnect the gear release link (E) from the hole in the charge roll link (F).
Note: Lift the upper front cover to make it easier to remove the link.
9.
Disconnect the main drive motor cable from the main drive assembly.
10.
Remove the main drive assembly.
Warning: Whenever the main drive assembly is removed from the printer it must be handled very carefully.
Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage. It is also very important not to let any dirt, paper, staples, or other material come in contact with the grease in the gears.
Note: Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly.
4-114 Service Manual
Modem removal
1.
Remove the two screws (A) on the rear of the MFP.
7002-xxx
A
2.
Disconnect the cable (B) from the scanner control card.
3.
Remove the cable from the slot in the frame (C).
4.
With a flathead screwdriver open the cable clamp (D), and remove the cable and the modem.
C D B
Repair information 4-115
7002-xxx
MPF arm assembly removal
1.
Open the left door.
2.
Remove the MPF lower front cover. See
“Multipurpose feeder/lower front cover assembly removal” on page 4-71 .
3.
Remove the MPF lower paper deflector. See “MPF lower paper deflector” on page 4-117 .
4.
Remove the upper paper deflector. See
“Upper paper deflector assembly removal” on page 4-138 .
5.
Remove the inner paper deflector. See
“Inner paper deflector assembly removal” on page 4-101
.
6.
Remove the MPF solenoid assembly. See
“MPF solenoid assembly removal” on page 4-119
.
7.
Remove the C-clip (A).
8.
Remove the washer, and set it aside.
9.
Remove the MPF arm assembly.
4-116 Service Manual
Installation note:
Note the order of C-clips bushing, and washer when you reinstall.
7002-xxx
MPF lower paper deflector
1.
Remove the MPF lower cover.
2.
Remove the four screws securing the MPF lower paper deflector.
3.
Remove the defector.
Repair information 4-117
7002-xxx
MPF pick tire removal
1.
Remove the upper paper deflector. See
“Upper paper deflector assembly removal” on page 4-138 .
2.
Release the pick roll retaining tab (A), and slide the pick roll off the shaft.
A
4-118 Service Manual
7002-xxx
MPF solenoid assembly removal
1.
Open the left door.
2.
Remove the MPF lower front cover. See
“Multipurpose feeder/lower front cover assembly removal” on page 4-71 .
3.
Remove the MPF lower paper deflector. See “MPF lower paper deflector” on page 4-117 .
4.
Remove the upper paper deflector. See
“Upper paper deflector assembly removal” on page 4-138 .
5.
Remove the C-clip (A) on the left side.
6.
Press the clips on the end of the shaft to remove the MPF tires (B).
7.
Remove the C-clip (C) on the shaft.
C B
Repair information 4-119
7002-xxx
8.
Remove the bushing (D).
Note: The bushing fits into a detent (E) in the frame of the MPF arm assembly.
9.
Loosen the paper alignment screws (F).
F
10.
Remove the C-clip securing the MPF solenoid assembly on the shaft.
Note: This C-clip is very difficult to locate and remove.
4-120 Service Manual
7002-xxx
11.
Pull the shaft assembly (G) to the right until the left end of the shaft is clear of the frame, and slide the MPF solenoid assembly from the shaft.
Installation note:
Be careful not to lose the washer (H) that is between the MPF solenoid assembly and the C-clip. It belongs to the
MPF arm assembly.
H
Repair information 4-121
7002-xxx
Paper alignment assembly removal
1.
Remove the upper paper deflector assembly. See
“Upper paper deflector assembly removal” on page 4-138
.
2.
.
3.
Release the input paper sensor from its mounting, and remove.
4.
Remove the left door.
5.
Remove the paper alignment assembly mounting screws (A).
4-122 Service Manual
7002-xxx
6.
Locate the paper alignment assembly reference adjustment screw (B) through the left frame, and remove the screw.
B
7.
Remove the paper alignment assembly.
Note:
Do the “Paper alignment assembly adjustment” on page 4-3
when you reinstall the assembly.
Repair information 4-123
7002-xxx
Paper bin full sensor flag removal
1.
Remove the left door. See “Printer left side cover removal” on page 4-56
.
2.
Remove the upper sub cover. See
“Upper sub cover removal” on page 4-55 .
3.
Remove the fuser wiper cover assembly. See “Fuser wiper cover assembly removal” on page 4-54
4.
Remove the two screws (A) attaching the upper plenum and remove the upper plenum.
A
5.
Remove the screws from the upper cover. See
“Upper cover removal (printer)” on page 4-133 .
Note: It is not necessary to remove the cover from the printer.
6.
Lift the left rear corner of the printer upper top cover to access the flag (B) and remove the flag from the mounting bracket.
4-124 Service Manual
7002-xxx
Paper size sensing board removal
1.
Remove the system board and inner shield. See
“System board and inner shield removal —models
.
2.
Remove the paper size sensing board mounting screw (A).
3.
Disconnect the paper size sensing board cable (B) from the board.
4.
Remove the paper size sensing board from the latch (C).
C
5.
Remove the paper size sensing board.
A B
Repair information 4-125
7002-xxx
Power takeoff shaft and spring removal
Remove the power takeoff shaft and spring (A) through the bottom of the printer.
Printer outer shield removal
1.
Remove the printer left door. See
“Printer left side cover removal” on page 4-56 .
2.
Loosen the outer shield mounting screws (A), and remove the shield by sliding up.
A(202)
4-126 Service Manual
A(202)
7002-xxx
Printhead removal
CAUTION
The laser scanning unit is not a serviceable FRU. Replace the entire unit when service is required.
1.
Remove the ADF scanner. See
“ADF complete assembly removal” on page 4-15
.
2.
Remove the flatbed scanner. See “Flatbed scan assembly removal” on page 4-38 .
3.
Remove the printer upper cover. See “Upper cover removal (printer)” on page 4-133
.
4.
Disconnect the printhead cable (A) from the printhead assembly.
5.
Remove the four printhead mounting screws (B), and remove the printhead.
Note:
Do the “Printhead assembly adjustment—printer” on page 4-2
whenever you remove or replace the printhead assembly or loosen the mounting screws.
B A
Repair information 4-127
7002-xxx
Redrive assembly removal
1.
Remove the redrive door assembly.
2.
Remove the redrive exit cover.
3.
Remove the redrive assembly mounting screws (A).
4.
Release the redrive assembly mounting latches (B), and remove the redrive assembly.
4-128 Service Manual
Signature button contact assembly removal
1.
Remove the print cartridge.
2.
Remove the left side door. See
“Printer left side cover removal” on page 4-56 .
3.
Remove the right cover. See
“Printer right cover removal” on page 4-58 .
4.
Remove outer system board shield. See
“Printer outer shield removal” on page 4-126 .
5.
Disconnect signature button cable from connector J14 on the system board.
6.
On models 200/210/400/410, remove the two screws (A) securing the blower duct.
7002-xxx
7.
Remove the signature button contact assembly mounting screw (B).
8.
Remove the assembly signature button contact assembly.
Note: Be sure to route the cable in the same location, as shown (C), when replacing the assembly.
Repair information 4-129
7002-xxx
System board and inner shield removal—model X642e
Warning: When replacing any one of the following components:
• Flatbed interconnect card (ICC)
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
Warning:
1.
Remove the outer shield. See
“Printer outer shield removal” on page 4-126 .
2.
Disconnect all cables from the system board.
Note: Sometimes cables may be difficult to remove. Be careful not to damage the connectors.
3.
Remove all features and options from the interface card.
4.
Depending on your printer model, remove the small USB port mounting screw (A).
Note: You may have additional screws in various models.
5.
Depending on your printer model, remove the modem. See
.
6.
Remove the six system board mounting screws (B).
Back view Side view
A
7.
Remove the system board and inner shield.
B
4-130 Service Manual
7002-xxx
System board and inner shield removal —models X644e/X646e
Warning: When replacing any one of the following components:
• Flatbed interconnect card (ICC)
• System board assembly
• Interface card assembly
Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never replace two or more of the components listed above without a POR after installing each one, or the printer will be rendered inoperable.
Warning: Never install and remove components listed above as a method of troubleshooting components.
Once a component has been installed in a printer, it cannot be used in another printer. It must be returned to the manufacturer.
Warning:
1.
Remove the outer shield. See
“Printer outer shield removal” on page 4-126 .
2.
Disconnect all cables from the system board.
Note: Sometimes cables may be difficult to remove. Be careful not to damage the connectors.
3.
Remove all features and options from the interface card.
4.
Depending on your printer model, remove the small USB port mounting screw (A).
Note: You may have additional screws in various models.
5.
Depending on your printer model, remove the modem. See
.
6.
Remove the six system board mounting screws (B).
Back view Side view
A
7.
Remove the system board and inner shield.
B
Repair information 4-131
7002-xxx
Toner sensor removal
1.
Remove the right side cover. See
“Printer right cover removal” on page 4-58
.
2.
Remove the toner sensor mounting screw (A).
3.
Disconnect the toner sensor cable, and remove the toner sensor.
Transfer roll assembly removal
Warning: Be careful when handling the transfer roll. Wrap a piece of plain white paper around the charge roll to prevent contamination or damage.
1.
Open the upper front cover, and remove the print cartridge.
2.
Unsnap the transfer roll assembly from the left pivot arm.
3.
Lift the transfer roll assembly toward the left, and remove it from the printer.
4-132 Service Manual
Upper cover removal (printer)
1.
Remove the ADF scan assembly. See
“ADF complete assembly removal” on page 4-15
2.
Remove the flatbed scan assembly. See
“Flatbed scan assembly removal” on page 4-38 .
3.
Remove the left door. See “Printer left side cover removal” on page 4-56
.
4.
Remove the right cover. See
“Printer right cover removal” on page 4-58 .
5.
Remove the upper tray cover. See
“Upper tray cover removal (paper support)” on page 4-56 .
6.
Remove the upper sub cover. See
“Upper sub cover removal” on page 4-55
.
7.
Remove the fuser wiper cover. See “Fuser wiper cover assembly removal” on page 4-54
.
8.
Remove the two screws (A) attaching the upper plenum and remove the upper plenum.
7002-xxx
A
9.
Remove the screw (B) at the rear of the printer and the larger screw (C) at the front on the right side.
Repair information 4-133
7002-xxx
10.
Remove the two screws (D) from the top of the right side.
11.
Remove the two screws (E) from the top of the left side.
12.
For those models with a hard disk (X646e), remove the hard disk. See
“Hard disk removal” on page 4-44
.
4-134 Service Manual
13.
Remove the screw (F) through the back of the shield or from the position shown.
7002-xxx
14.
Unlatch the front right and front left cover posts, and remove the upper cover.
Note: Make sure the paper bin full sensor (G) clears the opening will lifting the upper cover.
Repair information 4-135
7002-xxx
Upper front cover hinge assembly removal
1.
Remove the ADF scan assembly. See
“ADF complete assembly removal” on page 4-15 .
2.
Remove the flatbed scan assembly. See
“Flatbed scan assembly removal” on page 4-38 .
3.
Remove the operator panel left cover assembly. See
“Operator panel left cover assembly removal” on page 4-61
.
4.
5.
Remove the touchscreen bezel. See
“Touchscreen bezel removal” on page 4-66 .
6.
Remove the LCD touchscreen. See
“LCD touchscreen removal—models X644e and X646e” on page 4-67
.
7.
Remove printer left side cover. See “Printer left side cover removal” on page 4-56
.
8.
Remove printer right side cover. See
“Printer right cover removal” on page 4-58 .
9.
Remove the printer upper cover. See “Upper cover removal (printer)” on page 4-133
.
10.
Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins, and remove the pins. Note the pin orientation and the C-clip location on the inside of each hinge.
11.
Detach the two springs (B) from the upper front cover hinges.
12.
Detach two springs (C) from the left and right side of the hinge assembly.
C B A B C
13.
Disconnect the USB cable and cover open switch cable from the system board and UICC (18-pin) to scanner control card cable from the scanner control card.
4-136 Service Manual
7002-xxx
14.
Remove the screw (D) attaching the hinge right side cable retainer and removal the UICC (18-pin) to scanner control card cable from the hinge arm.
D
15.
Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket.
16.
Lift the left pivot arm from the bracket, and move the upper cover hinge assembly toward the left to clear the right upper cover pivot arm from the mounting bracket.
17.
Remove the upper front cover hinge assembly.
Repair information 4-137
7002-xxx
Upper paper deflector assembly removal
1.
Either lift the ESD cover out of the way or remove it. See
“ESD cover removal” on page 4-78 .
Note: The tabs holding the ESD cover are easily stressed or broken.
2.
Lift the left side to release the small tab (A) on the left and the MPF flag (B) and slide the upper paper deflector assembly to the right to unlatch the hooks (C) on the right.
Note: Be careful not to put too much stress on the small tab (A) on the right.
3.
Lift to remove the upper paper deflector assembly.
Installation note : Make sure the MPF flag (B) is in place.
4-138 Service Manual
USB card
1.
Remove the printer left side cover. See
“Printer left side cover removal” on page 4-56 .
2.
Remove the operator panel left cover. See
“Operator panel left cover assembly removal” on page 4-61
.
3.
Remove the USB cable (A) from the USB board assembly.
4.
Remove the two screws (B) securing the USB board assembly.
Note: Models X644e/X646e shown.
7002-xxx
B
5.
Remove the USB card.
A
Repair information 4-139
7002-xxx
4-140 Service Manual
5. Locations and connections
Locations
Sensors—flatbed
Model X642e
7002-xxx
Models X644e/X646e
Locations and connections 5-1
7002-xxx
Sensors—ADF
Model X642e
Models X644e/X646e
5-2 Service Manual
Connections
System board
Models X644e/X646e Model X642e
7002-xxx
Locations and connections 5-3
7002-xxx
System board (see
) connector pins
Pin no.
Connector
J1 Interconnect card
J2 Printhead (laser cable)
J3 Printhead (HSYNC)/mirror motor
J4 Main fan
J5 Cartridge fan
J6 Hopper full (output bin sensor)
3
1
1
2
12
1
2
3
2
3
8
9
10
11
6
7
4
5
13
1
2
3
9
10
11
12
7
8
5
6
3
4
1
2
FANSTALL
Ground
MAINFAN
CARTFANSTAIL
Ground
CARTFAN
HOP FULL*
Ground
HOP LED
Signal
VIDEO 1+ CN
VIDEO 1- CN
Ground
LADJ2*
VIDEO 0- CN
VIDEO 0+ CN
Ground
+5PHEAD
LPOW
Ground
LADJ* CN
LPOW FB
LENA*
Ground
HSYNC CN*
HSYNC ID
+5 V dc
5-4 Service Manual
System board (see “System board” on page 5-3 ) connector pins
Connector
J7 USB port
J8 Cover closed switch
J10 Fuser DC
J14 Signature button
J15 HVPS input sensor
Cartridge toner wheel sensor
Pin no.
1
2
1
9
10
11
6
7
8
3
4
5
3
1
2
7
1
2
4
5
6
1
2
3
11
12
13
8
9
10
5
6
7
2
3
4
Signal
Cov Closed
Ground
+5 V dc
NARMEDIA*
Ground
THERM
Ground
THUMP
+5V dc
THUMPRET
EXIT SNS*
+3.3 V dc
I2C CLK L5
I2C DAT L5
SM Cart
Ground
ATSERVO
TXENABLE
XFR
24 V dc switched
CHARGE
Ground
DEV
Ground
INPUTSENSX
+5 V dc switched
+5 V dc
TONER WHEELX
Ground
7002-xxx
Locations and connections 5-5
7002-xxx
System board (see “System board” on page 5-3 ) connector pins
Connector
J16 Ethernet port
Pin no.
10
11
12
7
8
9
13
4
5
6
1
2
3
J17 Parallel port
J18 Front/bottom options
J20 Transport motor
J21 Autoconnect—front/bottom
J23 MPF pick solenoid
J24 Autocomp motor
J25 Autoconnect—bottom/front
2
1
2
1
2
3
4
1
9
1
2
6
7
8
3
4
5
1
2
1
2
Signal
Ground
+24 V dc OTC OPT
BLDC_HALL 0
BLDC_HALL 1
BLDC_HALL 2
BLDC FG
Ground
+5 V dc switched
BLDC WIND
BLDC WIND 1
BLDC WIND 2
Ground
+5 V dc fused
Ground
+24 V dc PTC OPT
MPFPick*
+24V dc
+24 V dc
AUTOCOMP*
Ground
+24VPTCOPT
5-6 Service Manual
System board (see “System board” on page 5-3 ) connector pins
Connector
J26 Paper size sensor/autocomp motor
J27 LVPS
J28 MPF paper out
Pin no.
12
13
14
9
10
11
6
7
8
3
4
5
10
1
2
7
8
9
4
5
6
1
2
3
18
19
20
15
16
17
1
2
3
Signal
PSIZE2
Ground
PSIZE1
PSIZE3
Ground
TRAY1 POUT
TRAY1 PLOW*
+3.3V dc
ENCODER
+5V dc
+5 V dc
+5 V dc
+5 V dc
Ground
Ground
Ground
Ground
Ground
Ground
Ground
+24 V dc RAW
Ground
+24 V dc RAW
+24 V dc RAW
ZEROXING R+
+24 V dc RAW
HEAT
HEAT
Ground
L FAN DRV*
MPF POUT
Ground
MPF LED
7002-xxx
Locations and connections 5-7
7002-xxx
System board (see “System board” on page 5-3 ) connector pins
Connector
J30 USB host–back
USB host—front connection
Printhead fan
Pin no.
3
4
5
1
2
7
1
2
4
5
6
1
2
3
Autoconnect
Connector
Bottom autoconnect
Pin no.
3
4
5
1
2
6
Signal
+5 V USBICN
USB DI–
USB DI+
Ground
Ground
+24V dc
PH FAN*
Signal (static)
+24 V dc
0 V dc
+5 V dc
0 V dc
0 V dc
0 V dc
Front autoconnect
3
4
1
2
5
6
0 V dc
0 V dc
0 V dc
+5 V dc
0 V dc
+24 V dc
5-8 Service Manual
Fuser board
Fuser Board (not a FRU)
High voltage power supply
Connector
CN1 System board
7002-xxx
Connectors
J1—System board
J2—Narrow media sensor
J3—N/A
J4—Solenoid
J5—Exit sensor
J6—Thermistor
CN no.
7
8
5
6
3
4
1
2
Signal
Developer PWM
+24 V dc Return
Charge PWM
+24 V dc IN
TX PWM
TX Enable
TX CUR PWM
SVRO OUT
Locations and connections 5-9
7002-xxx
Interface card
Connector Pin no.
Signal
USB card
Connector
CN2
J2
Pin no.
1-5
Signal
Signals
USB signals
5-10 Service Manual
Low voltage power supply
Connector
CN1 Fuser lamp AC
CN2 DC output
7002-xxx
CN pin no.
1
2
3
Signal
AC fuser lamp
Not used
AC fuser lamp
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
Heat on
+5 V dc
+5 V dc
Ground
Ground
Ground
Ground
+24 V dc
ZC Out*
+42 V dc
+5 V dc
+5 V dc
Ground
Ground
Ground
Ground
+24 V dc
+24 V dc
Locations and connections 5-11
7002-xxx
Operator panel card (UICC #1)—model X642e
Note: Part of operator panel right cover assembly.
Model X642e
Operator panel card connector pins—model X642e
Connector
J3 to touchscreen display
CN pin no.
3
4
1
2
Signal
X-DRIVE +5 V dc IN
X+/Y +DRIVE
Y+/X +DRIVE
Y-/X +5 V dc IN
J5 Not used
J7 Not used
J10 to J15 on scanner control card
9
10
11
6
7
8
12
3
4
5
1
2
+24 V dc
+24 V dc
Ground
Ground
TXD-
TXD+
TXD232 N
RXD232 N
Ground
Ground
CLKTX-
CLKTX+
5-12 Service Manual
7002-xxx
Operator panel card connector pins—model X642e (continued)
Connector
J10 to J15 on scanner control card (continued)
J12 to touchscreen display
J14
CN pin no.
16
17
18
13
14
15
1–32
1
2
J15
J18 to CN1 on LCD inverter card
1
2
7
8
3
5
6
3
4
4
1
2
Signal
NC TX2-
NC TX2+
NC TXI-
NC TXI+
MASTER RESET N
Ground
Signal
+5 V dc IN
BUTTON ADMIN (+5 V dc default, ground when pushed)
Ground
V o
(contrast wheel output)
V o
(contrast wheel output)
Ground
V
EE
± 24 V dc
V
EE
± 24 V dc
+5 V dc IN
BUTTON HOME
BUTTON HELP (+5 V dc default, ground when push Go)
Ground
+5 V dc BACKLIGHT CONTROL
Ground
Locations and connections 5-13
7002-xxx
Operator panel card (UICC #1)—models X644e/X646e
Note: Part of operator panel right cover assembly.
Models X644e/X646e
Operator panel card connector (UICC #1) pins—model X644e/X646e
Connector
J3 to touchscreen display
J5 Not used
J7 Not used
CN pin no.
3
4
1
2
1-4
1-14
Signal
X-DRIVE +5 V dc IN
X+/Y +DRIVE
Y+/X +DRIVE
Y-/X +5 V dc IN
Signal
Signal
5-14 Service Manual
Operator panel card connector (UICC #1) pins—model X644e/X646e (continued)
Connector
J10 to J15 on scanner control card
J12 to touchscreen display
J13 to CN1 on inverter card
CN pin no.
1–32
1
2
3
4
5
6
7
8
16
17
18
13
14
15
10
11
12
7
8
9
4
5
6
1
2
3
Signal
+24 V dc
+24 V dc
Ground
Ground
TXD-
TXD+
TXD232 N
RXD232 N
Ground
Ground
CLKTX-
CLKTX+
NC TX2-
NC TX2+
NC TXI-
NC TXI+
MASTER RESET N
Ground
Signal
+12 V dc
+12 V dc
Ground
Ground
BACKLITE CONTROL
PWM DIM
Ground
Ground
7002-xxx
Locations and connections 5-15
7002-xxx
LCD inverter board (IUCC #2)
Note: Part of operator panel left cover.)
Model X642e Models X644e/X646e
Connector
CN1 to J13 on operator panel card
(Model X642e)
CN1 to J13 on operator panel card
(Model X644e/X646e)
CN2 to touchscreen display
CN pin no.
1
2
3
1
2
4
5
4
6
2
3
8
1
6
7
Signal
+5 V dc BL
Ground
+12 V dc
+12 V dc
Ground
Ground
BACKLITE CONTROL—Lamp on/ off control
PWM DIM—Bright adjust
Ground
Ground
HV DO NOT MEASURE
Not used
Not used
Not used
HV DO NOT MEASURE
5-16 Service Manual
Scanner control card
Models X642e Models X644e/X646e
7002-xxx
Scanner control card connector pins
Connector
J1 to CN1 on flatbed interface card
CN pin no.
13
14
15
16
9
10
11
12
17
18
19
7
8
5
6
3
4
1
2
Signal
MDC DET
+25 V dc IN
+25 V dc IN
+25 V dc IN
Ground nTOP FB nTOP ADF
Ground nSTART LINE
Ground
MDC TXD
MDC RXD
Ground nADF Present nCOVER CLOSED
Ground
FAN ON
FAN BACK
Ground
Locations and connections 5-17
7002-xxx
Scanner control card connector pins (continued)
Connector
J1 to CN1 on flatbed interface card (continued)
J2 FB CCD ribbon cable
J3 Not used
J4 Not used
J5 Not used
J7 To hard disk assembly (model X646e only)
J12 to hard disk (model X646e only)
Signal nRESET
+3.3 V dc
Ground
Signal
Signal
Signal
Ground
VXADF RXD2
VXADF TXD2
+5 V dc
Ground
MDC RXD
MDC TXD
+5 V dc
Ground
VXADF RXD1
VXADF TXD1
+5 V dc
+12 V dc
Ground
Ground
+5 V dc
+5 V dc
Ground
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Signal
CN pin no.
4
1
2
1
2
3
2
3
4
3
4
1
4
1
2
1
2
3
20
21
22
23
24
1-36
12
13
14
9
10
11
15
16
6
7
8
3
4
5
5-18 Service Manual
Scanner control card connector pins (continued)
Connector
J12 to hard disk (model X646e only) (continued)
J13 to J59 on modem card
Signal
Signal
Ground
Signal
+5 V dc
Ground
Signal
Signal
Signal
Signal
Signal
Ground
+5 V dc
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Ground
HARD KEY
Signal
Signal
Ground
+3.3 V dc
+3.3 V dc
Signal
Signal
Signal
Signal
Ground
Signal
Signal
Signal
Signal
Signal
Signal
CN pin no.
39
40
1
36
37
38
33
34
35
29
30
31
26
27
28
23
24
25
20
21
22
17
18
19
11
12
13
8
9
10
14
15
5
6
7
2
3
4
7002-xxx
Locations and connections 5-19
7002-xxx
Scanner control card connector pins (continued)
Connector
J13 to J59 on modem card (continued)
J15 to operator panel card
Signal
Ground
UITXD
UIRXD
TX0-
TX0+
Ground
Ground
+24 V dc
+24 V dc
Signal
Signal
Signal
Signal
Signal
Signal
Ground
DSP-IRQ
IO-WRITE
IO-READ
MOD CS
Ground
MOD RDY
MOD PRES
RESET N
MASTER RESET N
Ground
TX1-
TX1+
TX2-
TX2+
CLKTX-
CLKTX+
Ground
CN pin no.
7
8
9
4
5
6
1
2
3
28
29
30
25
26
27
22
23
24
19
20
21
16
17
18
13
14
15
10
11
12
16
17
18
5-20 Service Manual
Scanner control card connector pins (continued)
Connector
J23 to CN5 on flatbed interconnect card
7002-xxx
Signal
Ground
Signal
Signal
Ground
Signal
Signal
Ground
Signal
SDI
SEN
Signal
Ground
Ground
Ground
CCD ON
POWER SAVER
+24 V dc IN
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Signal
Signal
Ground
Signal
Signal
Signal
Signal
CCD CLAMP
CCD RESET
CCD PHRASE
CCD TRANSFER
CCD BW SELECT
+24 V dc IN
Ground
CN pin no.
20
21
22
17
18
19
14
15
16
11
12
13
8
9
10
5
6
7
2
3
4
C1
C2
1
32
33
34
29
30
31
35
36
26
27
28
23
24
25
Locations and connections 5-21
7002-xxx
Scanner control card connector pins (continued)
Connector
J28—ADF CCD (X644e/X646e)
Signal
CCD DET R
ADF HOME ON
ADF POWER SAVER
+24 V dc LAMP
+24 V dc LAMP
ADF CCD BW SEL
Ground
ADFR CCD TRANS
Ground
ADFR CCD PHASE 1
Ground
ADFR CCD RESET
Ground
ADFR CCD CLAMP
Ground
ADFR CCD CLK
Ground
ADFR AFE RSAMP
Ground
ADFR AFE VSAMP
Ground
ADFR AFE D
ADFR AFE D
Ground
ADFR AFE D
ADFR AFE D
Ground
ADFR AFE D
ADFR AFE D
Ground
ADFR AFE D
ADFR AFE D
Ground
ADFR AFE SEN
ADFR AFE SCK
ADFR AFE SD1
CN pin no.
22
23
24
19
20
21
16
17
18
13
14
15
10
11
12
7
8
9
4
5
6
1
2
3
34
35
36
31
32
33
28
29
30
25
26
27
5-22 Service Manual
Motor driver board
7002-xxx
Motor drive board connector pins
Connector
CN2 to ADF feed motor
CN3 to ADF scan motor
CN5 to pick arm solenoid
CN6 to flatbed interconnect card
CN pin no.
4
5
6
1
2
3
2
C1
C2
5
6
1
7
8
9
10
2
3
4
5
6
1
1
2
3
4
Signal
A
+25 V dc
Na
B
+25 V dc
VBB
OUT A
+25 V dc
OUT nA
OUT B
OUT nB
+25 V dc
SOL ON
+25 V dc
Ground
Ground
MDC ON
+25 V dc
+25 V dc nTOP ADF nSTART LINE
MDC TXD
Ground nCOVER CLOSED
OUT A
OUT A
Locations and connections 5-23
7002-xxx
Motor drive board connector pins (continued)
Connector
CN6 to flatbed interface card (continued)
CN7 to cover closed and cover closing sensors
CN8 to paper tray sensor
Signal
OUT B
OUT B
Ground nFLAT LENGTH1 nFLAT LENGTH3
Ground
FAN BACK nRESET
+25 V dc
+25 V dc nTOP FB
Ground
Ground
MDC RXD nADF PRESENT
Ground
OUT nA
OUT nA
OUT nB
OUT nB
Ground nFLAT LENGTH2 nHOME
FAN ON
+5 V dc
Ground
+5 V dc IN nCOVER CLOSING
Ground
+5 V dc IN nCOVER CLOSED
Ground
Ground
ADF WIDTH1
ADF WIDTH2
Ground nADF LENGTH
+5 V dc IN
CN pin no.
32
33
34
29
30
31
26
27
28
23
24
25
20
21
22
17
18
19
14
15
16
11
12
13
2
3
4
5
6
5
6
1
2
3
4
35
36
1
5-24 Service Manual
Motor drive board connector pins (continued)
Connector
CN9 to ADF exit sensor, ADF second scan sensor
CN10 to jam remove sensor, ADF paper present sensor, interval sensor, first scan sensor
CN pin no.
7
8
9
4
5
6
10
11
12
1
2
3
7
8
9
4
5
6
1
2
3
Signal
Ground nADF EXIT
+5 V dc IN
Ground
+5 V dc IN n2ND SCAN
Ground nADF COVER
+5 V dc IN
Ground nJAM REMOVE
+5 V dc IN
Ground nADF PRESENT
+5 V dc IN
Ground nADF INTERVAL
+5 V dc IN
Ground
+5 V dc IN n1ST SCAN
7002-xxx
Locations and connections 5-25
7002-xxx
Flatbed interconnect card
Model X642e Models X644e/X642e
Flatbed interconnect card connector pins
Connector
J1 to CN6 on ADF motor drive card
Pin no.
11
12
13
14
7
8
9
10
15
16
17
5
6
3
4
C1
C2
1
2
Signal
Ground
Ground
MDC ON
+25 V dc
+25 V dc nTOP ADF nSTART LINE
MDC TXD
Ground nCOVER CLOSED
OUT A
OUT A
OUT B
OUT B
Ground nFLAT LENGTH1 nFLAT LENGTH3
Ground
FAN BACK
5-26 Service Manual
Flatbed interconnect card connector pins (continued)
Connector
J1 to CN6 on ADF motor drive card
J1 to CN6 on ADF motor drive card (continued)
J2 to CN2 on ADF CCD module
(models X644e/X646e)
Pin no.
3
4
5
36
1
2
33
34
35
30
31
32
27
28
29
24
25
26
21
22
23
18
19
20
12
13
14
15
16
9
10
11
6
7
8
Signal nRESET
+25 V dc
+25 V dc nTOP FB
Ground
Ground
MDC RXD nADF PRESENT
Ground
OUT nA
OUT nA
OUT nB
OUT nB
Ground nFLAT LENGTH2 nHOME
FAN ON
+5 V dc
Ground
7002-xxx
Locations and connections 5-27
7002-xxx
Flatbed interconnect card connector pins (continued)
Connector
CN1 to J1 on scanner control card
CN2 Flatbed scan motor
Pin no.
22
23
24
19
20
21
16
17
18
13
14
15
4
5
6
1
2
3
10
11
12
7
8
9
4
5
6
1
2
3
Signal
MOC DET
+25 V dc IN
+25 V dc IN
+25 V dc IN
Ground nTOP FB nTOP ADF
Ground nSTART LINE
Ground
MDC TXD
MDC RXD
Ground nADF PRESENT nCOVER CLOSED
Ground
FAN ON
FAN BACK
Ground nRESET
+3.3 V dc
Ground
Signal
Signal
OUT A
+25 V dc out nA
OUT B
+25 V dc
OUT nB
5-28 Service Manual
Flatbed interconnect card connector pins (continued)
Connector
CN3 Flatbed paper length sensor assembly
CN4 home sensor
CN5
Pin no.
8
9
10
5
6
7
2
3
4
C1
C2
1
11
12
13
14
1
2
3
7
8
9
4
5
6
1
2
3
Signal
Ground nFLAT LENGTH1
+5 V dc IN
Ground nFLAT LENGTH2
+5 V dc IN
Ground nFLAT LENGTH3
+5 V dc IN
Ground nHOME
+5 V dc IN
Ground
Ground
CCD ON
POWER SAVER
+24 V dc IN
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Ground
Signal
Signal
Ground
7002-xxx
Locations and connections 5-29
7002-xxx
Flatbed interconnect card connector pins (continued)
Connector
CN5 (continued)
Pin no.
33
34
35
36
30
31
32
27
28
29
24
25
26
21
22
23
18
19
20
15
16
17
Signal
Signal
Signal
Ground
Signal
SDI
SEN
Signal
Ground
Signal
Signal
Ground
Signal
Signal
Signal
Signal
CCD CLAMP
CCD RESET
CCD PHASE
CCD TRANSFER
CCD BW SE:LECT
+24 V dc IN
Ground
5-30 Service Manual
Modem card
Modem card connector pins
Connector
J68 on modem card
Signal
Signal
Ground
Signal
Signal
Signal
Signal
Signal
Signal
Signal
Ground
DSP-IRQ
IO-WRITE
+5 V dc
Ground
+3.3 V dc
+3.3 V dc
Signal
Signal
Signal
Signal
Ground
Signal
Signal
Signal
IO-READ
MOD CS
Ground
MOD RDY
MOD PRES
RESET N
Pin no.
22
23
24
19
20
21
16
17
18
13
14
15
28
29
30
25
26
27
10
11
12
7
8
9
4
5
6
1
2
3
7002-xxx
Locations and connections 5-31
7002-xxx
5-32 Service Manual
7002-xxx
6. Preventive maintenance
This chapter describes procedures for printer preventive maintenance. Following these recommendations can help prevent problems and maintain optimum performance.
Safety inspection guide
The purpose of this inspection guide is to aid you in identifying unsafe conditions.
If any unsafe conditions exist, find out how serious the hazard could be and if you can continue before you correct the hazard.
Check the following items:
• Damaged, missing, or altered parts, especially in the area of the on/off switch and the power supply.
• Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover.
•
Possible safety exposure from any non-Lexmark attachments.
Lubrication specifications
No requirements for this printer.
Scheduled maintenance
Maintenance kit
The operator panel displays the message
80 Scheduled Maintenance
at each 300K page count interval. It is necessary to replace the fuser assembly, transfer roller, charge roll, and pick tires at this interval to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part numbers:
Maintenance kits
Description
115 V Maintenance kit
220 V Maintenance kit
100 V Maintenance kit
Part number
40X0100
40X0101
40X0197
After replacing the kit, the maintenance count must be reset to zero to clear the “80 Scheduled Maintenance” message. See
“Maintenance Page Count” on page 3-25 .
Preventive maintenance 6-1
7002-xxx
Cleaning the scanner glass, cushions, and strips
1.
Open the document cover.
2.
Dampen a clean, lint-free cloth or cotton swab with isopropyl alcohol.
3.
Clean the following with the cloth or swab:
• Flatbed contact glass
• Flatbed white cushion
• Front flatbed white strip
• Glass slit in flatbed glass holder (see step 4).
All models
4.
Remove the flatbed glass holder and clean both sides of the glass slit. See
“Upper glass holder removal” on page 4-53 .
Warning: Be careful not to touch the white calibration strip (A) on the underside of the scanner flatbed glass holder.
6-2 Service Manual
7002-xxx
5.
For models X644e/X646e, remove the flatbed white cushion. See
“Flatbed white cushion removal” on page 4-32
.
6.
Press the release lever to open the lower exit guide
7.
Use the cloth or swab to clean the ADF CCD glass and back ADF white strip with the cloth or swab.
Models X644e/X646e
8.
Close the lower exit guide.
9.
Close the document cover.
Preventive maintenance 6-3
7002-xxx
6-4 Service Manual
7. Parts catalog
7002-xxx
How to use this parts catalog
The following legend is used in the parts catalog:
Asm-
Index
Part number
Units/mach
- OR -
Units/option
Units/ kit or pkg
Description
• Asm-index : identifies the assembly and the item in the diagram. For example, 3-1 indicates Assembly 3 and the item number 1.
• Part number : identifies the unique number that identifies this FRU.
• Units/mach : refers to the number of units actually used in the base machine or product.
• Units/option: refers to the number of units used in the option and does not include the base machine.
• Units/kit or pkg : refers to the number of units packaged together and identified by the part number.
• PP : (Parts Packet) in the parts description column indicates the part is contained in a parts packet.
• NS : (Not shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration.
• NA : (Not available) in the parts description column indicates the part is shown for identification purposes only and is not available as a FRU.
Model information used in the parts catalog.
Model name
Lexmark X644e
Lexmark X642e
Lexmark X642e
Lexmark X644e
Lexmark X646e
Lexmark X646e
Lexmark X644e
Lexmark X642e
Lexmark X642e
Lexmark X644e
Lexmark X646e
Lexmark X646e
Configuration
Network
Network
Network, modem
Network, modem
Network, hard disk
Network, modem, hard disk
HV, network
HV, network
HV, network, modem
HV, network, modem
HV, network, hard disk
HV, network with hard disk
Machine type
7002-001
7002-003
7002-005
7002-011
7002-101
7002-111
7002-002
7002-004
7002-006
7002-012
7002-102
7002-112
Parts catalog
001
003
005
011
101
111
002
004
006
012
102
112
Parts catalog 7-1
7002-xxx
Assembly 1: Covers—printer (model X642e)
7-2 Service Manual
7002-xxx
Assembly 1: Covers—printer (model X642e)
Asm-
Index
1—1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part number
40X0001
40X0469
40X0467
40X0468
40X0473
40X0471
40X0516
40X3309
Units/ mach
1
1
1
1
1
1
2
1
40X3303
40X0493
40X3301
40X3299
40X3302
40X0151
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Fuser wiper cover assembly
Upper sub cover assembly
Upper cover assembly
Upper tray cover (paper support)
Right side cover
Right cover assembly
Counterbalance spring
Upper front cover hinge assembly—X642e, includes:
• Operator panel frame (hinge)
• UICC 18-pin cable
• USB cable
• Cover open sensor
• Left hinge cable retainer
• Right hinge cable retainer
• Left hinge spring
• Right hinge spring
• Ground cable
• Screw, M3x10 (3)
• Screw, Sunk head (1)
Operator panel right cover assembly—X642e, includes:
• Operator panel right cover
• Dial numeric pad key
• Control 1—Stop key
• Control 2—Go key
• Control 3—Clear key
• Hook, operator panel right assembly
• Compression spring
• LCD operator panel cap
• UICC #1 card assembly
• Screw, M3x8 (2)
• Screw, M3x8 (2)
Multipurpose tray assembly
LCD mono touchscreen display assembly—X642e, includes:
• LCD lower cover
• Mono LCD assembly
• LCD frame lever
• LCD lever spring
• Core
• Screw, M3x8 (4)
Cover bezel with Lexmark logo—X642e, includes
• Bezel
• UICC #3
• Home key
• M3x8 screws (2)
Operator panel left cover assembly—X642e, includes
• Operator left cover
• Operator panel left hook
• Admin key
• UICC #2 card assembly
• Compression spring
• M3x18 screws (2)
• M3x18 screws (2)
USB board assembly
Parts catalog 7-3
7002-xxx
Assembly 1 (continued): Covers—printer (model X642e)
7-4 Service Manual
Assembly 1: Covers—printer (model X642e)
Asm-
Index
Part number
1—15 40X3304
16 40X0009
17
18
NS
40X0470
40X0472
NS
NS
40X0050
40X5651
Units/ mach
1
1
5
2
1
1
1
Units/ kit or pkg
1
1
10
1
1
1
1
Description
LCD (mono) touchscreen inverter card—X642e
TLI/ID/serial number label—blank
Left cover assembly
Left side cover
Parts packet (cable ties) (PP 40X0174)
Counterbalance spring
Vent cover
7002-xxx
Parts catalog 7-5
7002-xxx
Assembly 2: Cover—printer (models X644e and X646e)
7-6 Service Manual
15
16
17
18
NS
NS
12
13
14
10
11
12
Assembly 2: Covers—printer (models X644e and X646e)
Asm-
Index
2—1
2
3
4
5
6
7
8
9 40X0496
40X0493
40X0494
40X3313
40X0476
40X0495
40X0151
40X0497
40X0009
40X0470
40X0472
Part number
40X0001
40X0469
40X0467
40X0468
40X0473
40X0471
40X0516
40X0515
Units/ mach
1
1
1
1
1
1
2
1
40X0050
1
1
1
1
1
1
1
1
1
1
1
5
2
1
10
1
1
1
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
Description
Fuser wiper cover assembly
Upper sub cover assembly
Upper cover assembly
Upper tray cover (paper support)
Right side cover
Right cover assembly
Counterbalance spring
Upper front cover hinge assembly—X644e/X646e, includes:
• Cable, VICC 18-pin
• Hinge, operator panel
• USB cable (1)
• Cover open switch and cable (1)
• Left cable retainer (1)
• Right cable retainer (1)
• Left hinge spring (1)
• Right hinge spring (1)
Operator panel right cover assembly—X644e/X646e, includes:
• Stop button (1)
• Go button (1)
• Clear button (1)
• LED cap (1)
• Dial number pad
• User interface control card assembly
• Compression spring
• Operator panel right cover
• Operator panel right side hook
Multipurpose tray assembly
LCD touchscreen display assembly—X644e/X646e
Cover bezel with Lexmark logo—X644e
Cover bezel with Lexmark logo—X646e
Operator panel left cover assembly—X644e/X646e
USB board assembly
LCD touchscreen inverter card
TLI/ID/serial number label—blank
Left cover assembly
Left side cover
Parts packet (cable ties) (PP 40X0174)
Counterbalance spring
7002-xxx
Parts catalog 7-7
7002-xxx
Assembly 3: Covers—ADF scanner
7-8 Service Manual
Assembly 3: Covers—ADF scanner
Asm-
Index
6
7
8
9
3—1
2
3
4
5
Part number
40X0450
40X3296
40X0451
40X3297
40X0452
40X0463
40X0465
40X0464
Units/ mach
1
1
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
Description
Complete ADF assembly—X644e/X646e
Complete ADF assembly—X642e
Document tray assembly—X644e/X646e
Document tray assembly—X642e
ADF top cover assembly
ADF scan cover
ADF rear cover
ADF front cover
Parts packet, sensors (PP 40X0481)
7002-xxx
Parts catalog 7-9
7002-xxx
Assembly 4: Frame 1
7-10 Service Manual
Assembly 4: Frame 1
Asm-
Index
6
7
8
9
4—1
2
3
4
5
Part number
40X0065
40X0225
40X0024
40X0026
40X0025
40X0060
40X0231
40X0285
Units/ mach
1
1
1
1
4
1
1
4
1
Units/ kit or pkg
1
1
1
1
4
1
1
1
1
Description
Frame extension, nut plate
Right side hand holder
Parts packet (PP 40X0165)
Right frame extension
Right side frame ground contact
Left frame extension
External ground clip
Left side hand holder
Frame clip
7002-xxx
Parts catalog 7-11
7002-xxx
Assembly 5: Frame 2
7-12 Service Manual
Assembly 5: Frame 2
Asm-
Index
9
10
11
6
7
8
5—1
2
3
4
5
12
13
14
15
16
NS
Part number
40X0027
40X0028
40X0030
40X0032
40X0044
Units/ mach
1
1
1
1
1
40X0048
40X0046
40X0049
40X0054
40X0051
40X0052
40X0058
40X0264
40X0232
40X0059
1
1
1
1
1
1
1
1
1
1
2
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
Description
Upper redrive deflector
Upper diverter spring
Redrive assembly—500-sheet in/500 out
Transfer deflector with brush
Gear guard
Parts packet (PP 40X0165)
Paper switch activate spring
Paper size sensing board assembly
Gear release link
Main fan with cable—500-sheet output
Standard bin level sensor
Standard bin level sensor bracket
Output paper level flag
Standard bin level sensor cable
Redrive door assembly 500 sheet
Extension guide
Parts packet, redrive mounting screws (P/N 40X0254)
7002-xxx
Parts catalog 7-13
7002-xxx
Assembly 6: Frame 3
7-14 Service Manual
14
15
16
17
9
10
11
12
13
Assembly 6: Frame 3
Asm-
Index
5
6
7
8
6—1
2
3
3
4
Part number
40X0249
40X0208
40X0034
40X0033
40X0223
40X0036
40X0306
Units/ mach
4
1
1
1
1
1
1
1
1
40X0213
40X0021
40X0040
40X0042
40X0039
40X0043
40X0209
40X0045
40X0207
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
Description
EP DC fan assembly
Blower duct
Parts packet (PP 40X0165)
Parts packet (PP 40X0165)
Signature button contact assembly with cable
Machine mounting pad
HVPS/input sensor/toner sensor cable assembly
Toner sensor assembly
High voltage contact kit, including:
• Charge roll contact (1)
• Doc/TAR/Dev contact (3)
• PC drum contact (1)
• Screw (5)
• Screw block (4)
Tray bias assembly
Cartridge holddown assembly
Upper paper feed deflector
Inner paper feed deflector
Developer support roller
Input sensor
Gear #60 MPF shield
ESD shield with label
EP duct
7002-xxx
Parts catalog 7-15
7002-xxx
Assembly 7: Scanner automatic document feeder (ADF)—pickup
Asm-
Index
7—1
Part number
40X0453
Units/ mach
1
Units/ kit or pkg
Description
Pickup assembly
7-16 Service Manual
Assembly 8: Scanner ADF—paper feed
7002-xxx
Asm-
Index
8—1
Part number
40X4656
Units/ mach
1
Units/ kit or pkg
1
Description
Upper entrance guide kit, including:
• A—Separator roller with hub
• B—Torque limiter
• C—Upper entrance guide
• D—Sub ADF separator guide
• E—Snap ring
Parts catalog 7-17
7002-xxx
Assembly 9: Scanner ADF—lower exit guide assembly
Asm-
Index
9—1
1
2
Part number
40X0460
40X3311
40X0458
Units/ mach
1
1
1
Units/ kit or pkg
1
1
1
Description
Lower exit guide assembly—X644e/X646e
Lower exit guide assembly—X642e
ADF CCD module assembly—X644e/X646e only
7-18 Service Manual
Assembly 10: Scanner ADF—motors and belts
7002-xxx
Asm-
Index
Part number
10—1 40X0482
Units/ mach
1
2
3
40X0461
40X0462
1
1
Units/ kit or pkg
1
Description
Belts, including:
1
1
• A—Timing belt 52M194
• B—Timing belt 52M172
• C—Timing belt motor 52M292
• D—Timing belt second transport 52M152
• E—Timing belt first transport 52M132
Note: Belt P/N stamped on belt.
• F—Timing belt knob 52M172
Feed motor (ADF feed)
ADF scan motor assembly
Parts catalog 7-19
7002-xxx
Assembly 11: Scanner ADF—sensors
7-20 Service Manual
7002-xxx
Assembly 11: ADF—sensors
Asm-
Index
Part number
11—1 40X0456
2 40X0481
Units/ mach
1
1
3 40X0486 1
Units/ kit or pkg
1
4
1
Description
Pickup arm assembly solenoid
Parts packet, sensors
• A—Second scan sensor
• B—Paper present
• C—Interval sensor
• D—First scan sensor
• E—ADF top cover open
• F—Flatbed cover open
• G—Jam access door
Note: There are four different sensors in the parts packet, some of the same sensors are used in different locations.
Motor driver card
Parts catalog 7-21
7002-xxx
Assembly 12: Scanner—flatbed
7-22 Service Manual
7002-xxx
Assembly 12: Scanner—flatbed
Asm-
Index
Part number
8
9
10
5
6
7
11
12
12—1 40X3298
1 40X0457
2
3
4
40X0483
40X0466
40X0475
40X0513
40X0514
40X0478
40X3312
40X0485
40X0490
40X0479
40X0480
Units/ mach
1
1
1
1
1
1
1
1
1
1
1
1
1
13
13
14
15
16
17
40X0491
40X0491
40X0474
40X0481
40X0487
40X0484
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Complete flatbed scanner assembly—X642e
Complete flatbed scanner assembly—X644e/X644e
Flatbed contact glass
Flatbed white cushion
Scan cover
Flatbed cover closed actuator
Flatbed cover closing actuator
Flatbed CCD module assembly
Flatbed interconnect card assembly—X642e
Flatbed interconnect card assembly—X644e/X646e
Belt tension spring
Flatbed CCD drive belt
Flatbed scan motor, including flatbed scan motor to flatbed interconnect card cable
Flatbed paper size sensor assembly (assembly includes 3 sensors)—
X644e/X646e
Flatbed paper size sensor assembly (assembly includes 3 sensors but only one sensor is required)—X642e
Front cover
Parts packet, sensors (home sensor)
Flatbed CCD ribbon cable
Glass holder assembly
Parts catalog 7-23
7002-xxx
Assembly 13: Printhead
Asm-
Index
Part number
13—1 40X0061
2
3 40X0062
Units/ mach
1
1
Units/ kit or pkg
1
Description
1
Laser printhead cable assembly
Parts packet (PP 40X0165) (printhead mounting screw)
Printhead assembly (includes all cables)
CAUTION
The printhead is not a serviceable FRU. Do not disassemble the printhead.
7-24 Service Manual
Assembly 14: Paper feed—autocompensator
7002-xxx
3
4
5
6
7
Asm-
Index
Part number
14—1 40X0066
2 40X0069
Units/ mach
1
1
40X4308
40X0072
40X0215
40X0074
2
1
1
1
Units/ kit or pkg
1
1
2
1
1
1
Description
Pick arm assembly—500-sheet
Parts packet, bellcrank assembly for—500-sheet tray
• Bellcrank (1)
• Spring (1)
Pick roll assembly
Paper out flag—500-sheet tray
Paper low/out sensor card assembly, 500-sheet
Parts packet (PP 40X0165) (hanger)
Paper size/autocompensator cable
Parts catalog 7-25
7002-xxx
Assembly 15: Paper feed—multipurpose feeder
7-26 Service Manual
7002-xxx
Assembly 15: Paper feed—multipurpose feeder
Asm-
Index
Part number
15—1 40X0079
2 40X0310
3
4
5
40X0076
40X0077
5
5
NS
Units/ mach
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
Description
Multipurpose feeder lower deflector assembly
Multipurpose feeder pick arm assembly with solenoid
Pick roll assembly
Multipurpose feeder paper out flag
Parts packet (PP 40X0165) (lower deflector mounting screw, 8 mm)
Parts packet (PP 40X0165) (lower deflector mounting screw, 12 mm)
Parts packet (PP 40X0165) (frame mounting screw)
Parts packet (PP 40X0165) (pick roll shaft clip)
Parts catalog 7-27
7002-xxx
Assembly 16: Paper feed—alignment
7-28 Service Manual
Assembly 16: Paper feed—alignment
Asm-
Index
Part number
16—1 40X0084
2
3
4
40X0085
40X0086
Units/ mach
1
1
1
NS 1
Units/ kit or pkg
1
1
1
1
1
Description
Paper feed alignment assembly paper feed
Parts packet (PP 40X0165) (clip ref ground mounting screw)
Reference ground clip
Parts packet (reference adjust)
• Screw, paper reference adjust (1)
• Washer, paper reference adjust (1)
• Nut, paper reference adjust (1)
Parts packet (PP 40X0165) (alignment asm mounting screw)
7002-xxx
Parts catalog 7-29
7002-xxx
Assembly 17: Integrated 500-sheet paper tray
7-30 Service Manual
Assembly 17: Integrated 500-sheet paper tray
Asm-
Index
Part number
17—1 40X0098
2 40X0099
3
4
5
6
7
40X0182
40X0103
40X0183
40X0105
40X0106
Units/ mach
4
1
1
2
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
Description
Tray assembly—500-sheet tray
Side restraint
Wear strip
Pass thru plate—500-sheet tray
Wear plate—500-sheet tray
Restraint pad
Back restraint
7002-xxx
Parts catalog 7-31
7002-xxx
Assembly 18: Drives—Main drive and developer drive
7-32 Service Manual
Assembly 18: Drives—Main drive and developer drive
Asm-
Index
Part number
18—1 40X0107
2 40X0111
3
4
40X0112
99A0954
Units/ mach
1
1
1
1
5
6
7
NS
40X0114
40X0115
1
Units/ kit or pkg
1
1
1
1
1
3
4
Description
Gearbox with motor
Power takeoff shaft—500-sheet
Power takeoff shaft spring
Bevel gear with grease packet and washer
• Bevel gear (1)
• Instruction sheet (1)
• Grease packet (1)
• washer (1)
Developer drive assembly
Parts packet, developer drive
• Developer drive shaft (1)
• shaft, coupler gear #55 (1)
Parts packet (PP 40X0165) (developer drive ground screw)
Parts packet (PP 40X0165) (gearbox mounting screw)
7002-xxx
Parts catalog 7-33
7002-xxx
Assembly 19: Hot roll fuser
7-34 Service Manual
Assembly 19: Hot roll fuser
Asm-
Index
Part number
19—1 40X2592
1 40X2591
1
2
3
3
4
40X2590
40X0120
40X0122
40X0123
40X0121
Units/ mach
1
1
1
1
1
1
1
5
6
7
8
9
10
11
12
13
NS
40X0239
40X0236
40X0125
40X0230
40X0238
40X0124
40X0229
40X0226
1
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Fuser assembly w/115 V lamp
Fuser assembly w/100 V lamp
Fuser assembly w/220 V lamp
Fuser wiper cavity cover
Fuser lamp, 115V
Fuser lamp, 220V
Fuser cover assembly kit, including:
• Thermistor (1)
• Thermostat (1)
• Left and right fuser lamp contact assemblies (1)
Parts packet (fuser mounting screw) (PP 40X0254)
Exit sensor flag/spring kit, including:
• Spring (1)
• Flag (1)
Exit/narrow media sensor cover
Parts packet (PP 40X0165)
Exit sensor
Exit sensor cable
Narrow media flag/spring kit, including:
• Spring
• Flag
Narrow media sensor
Narrow media sensor cable
Fuser AC to fuser lamp cable
7002-xxx
Parts catalog 7-35
7002-xxx
Assembly 20: Transfer/charging
7-36 Service Manual
Assembly 20: Transfer/charging
Asm-
Index
Part number
9
NS
NS
6
7
8
20—1 40X0126
2 40X0127
3
4
5
40X0129
40X0130
40X0131
40X0132
40X0133
40X0134
40X0135
Units/ mach
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
1
2
Description
Parts kit, charge roll link asm, left side
Charge roll assembly, dual
Parts kit, right side charge roll link assembly
Transfer roll assembly
Transfer roll assembly right arm
Transfer roll right spring
Transfer pivot shaft
Transfer roll left spring
Transfer roll left arm
Parts packet (PP 40X0165) (charge roll screw)
Parts packet (PP 40X0165) (C-clip, pivot shaft)
7002-xxx
Parts catalog 7-37
7002-xxx
Assembly 21: Electronics—power supplies
7-38 Service Manual
7002-xxx
Assembly 21: Electronics—power supplies
Asm-
Index
Part number
21—1 40X3244
1 40X3245
2 40X0260
Units/ mach
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
3
4
5
40X0256
40X0255
40X0257
40X0258
40X0293
40X4596
40X0301
40X0271
40X0272
40X0280
40X0303
40X0281
40X0294
40X0295
40X0304
40X0305
40X4275
40X0223
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
1
1
Description
LVPS/AIO—115 V ac
LVPS/AIO—220 V ac
Power cord set (8 ft right angle, 13 amp)—United States, Canada,
Caribbean countries, Colombia, Costa Rica, Dominican Republic, El
Salvador, Equator, Guatemala, Honduras, Mexico, Nicaragua, Panama,
Puerto Rico, Saudi Arabia, Venezuela, and Virgin Islands
Power cord set (8 ft right angle)—Bolivia and Peru
Power cord set (8 ft right angle)—Argentina
Power cord set (8 ft right angle)—Chile, Uruguay
Power cord set (8 ft right angle)—Arabic, Austria, Belgium, Bluemark, CIS,
Czechoslovakia, Denmark, Finland, France, Germany, Greece, Hungary,
Ireland, Italy, Medmark, (1 and 2), Netherlands, Norway, Paraguay, Poland,
Portugal, Russia, Slavic countries, Spain, Sweden, Turkey, and UK.
Power cord set (8 ft right angle)—Anguilla (UK), Antigua and Barbuda,
Bahrain, Botswana, Burma (Myanmar), Channel Islands, Cyprus,
Dominica, Falkland Islands, Gambia, Ghana, Gibraltar, Grenada, Guyana,
Hong Kong, Iraq, Ireland, Isle of Man, Jordan, Kenya, Kuwait, Lebanon,
Liberia, Malawi, Malaysia, Malta, Mauritius, Montserrat, Nigeria, Oman,
Pakistan, Pitcairn Island (UK), Qatar, Scotland, Seychelles, Sierra Leone,
Singapore, St. Kitts and Nevis, St. Lucia, St. Vincent and Grenadines,
Sudan, Tanzania, Trinidad and Tobago, Uganda, United Arab Emirates,
United Kingdom, Vanuatu, Wales, Yemen, Zambia, Zimbabwe.
Power cord set (6 ft right angle)—Brazil
Power cord set (8 ft straight)—AS/NZS
Power cord set (8 ft straight)—Hong Kong
Power cord set (8 ft right angle)—Japan
Power cord set (6 ft straight)—Korea
Power cord set (8 ft straight)—PRC
Power cord set (6 ft right angle)—Taiwan
Power cord set (8 ft right angle)—Denmark, Norway, and Sweden
Power cord set (8 ft right angle)—Israel
Power cord set (8 ft right angle)—Botswana, Lesotho, Namibia, Pakistan, and South Africa
Power cord set (8 ft right angle)—Switzerland
High voltage power supply
Parts packet (PP 40X0165)
Front cable harness (HVPS/input sensor/toner sensor)
Parts catalog 7-39
7002-xxx
Assembly 22: Electronics—card assemblies
7-40 Service Manual
7002-xxx
Assembly 22: Electronics—card assemblies
Asm-
Index
Part number
8
9
NS
7
7
7
NS
7
7
7
5
6
6
22—1 40X3305
1 40X0498
2
3
4
40X0509
40X0489
40X0520
40X0510
40X3310
40X2722
40X3477
40X2792
40X2529
40X2793
40X3479
40X4178
40X0519
40X0507
40X3478
40X4179
Units/ mach
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Scanner control card—X642e
Scanner control card—X644e/X646e
Hard disk IDE 50-pin cable—X646e
Hard disk assembly—X646e
Interface card assembly
Hard disk 4-pin power cable—X646e
System board assembly—X642e (Board ID M010 6030)
System board assembly (network)—X644e/X646e (Board ID M010 6000)
Bar code card assembly—X642e
Bar code card assembly—X644e/X646e
IPDS SCS/TNe card assembly—X644e/X646e
PRESCRIBE card assembly—X644e/X646e
PrintCryption card assembly—X642e
PrintCryption card assembly—X644e/X646e
Modem card assembly
Modem 30-pin cable
Forms card assembly—X642e
Forms card assembly—X644e/X646e
Note: The system board has a label with an board ID and barcode. Use the first eight numbers to identify the board with the part number in the table above:
Parts catalog 7-41
7002-xxx
Assembly 23: Electronics—shields
Asm-
Index
Part number
23—1 40X0150
2
2
2
3
4
5
40X0149
40X0153
40X0152
Units/ mach
1
1
1
1
Units/ kit or pkg
1
1
1
1
Description
Outer shield
Parts packet (PP 40X0165) (INA cover mounting screw)
Parts packet (PP 40X0165) (outer shield mounting screw)
Parts packet (PP 40X0165) (inner shield mounting screw)
Inner shield assembly
INA flat cover (blank)
Ethernet shield (blank)
7-42 Service Manual
Assembly 24: Cabling diagram 1
7002-xxx
1
2
3
Asm-
Index
Part number
24—1 40X0223
2 40X0160
3 40X0264
Units/ mach
1
1
1
Units/ kit or pkg
1
1
1
Description
HVPS/input sensor/toner sensor cable assembly
MPF sensor cable
Standard bin level sensor cable
Parts catalog 7-43
7002-xxx
Assembly 25: Cabling diagram 2
Asm-
Index
Part number
25—1 40X0061
2 40X0074
3 40X0046
Units/ mach
1
1
1
Units/ kit or pkg
1
1
1
Description
Laser printhead cable assembly
Paper size/autocompensator cable
Paper size sensing board assembly
7-44 Service Manual
1
2
3
Assembly 26: Cabling diagram 3
7002-xxx
Asm-
Index
Part number
26—1 40X0034
2 40X0156
3
4
40X0223
40X5224
Units/ mach
1
1
1
1
Units/ kit or pkg
1
1
1
1
Description
Signature button contact assembly with cable
Bottom/front autoconnect cable assembly
HVPS/input sensor/toner sensor cable assembly
LVPS to system board cable assembly
Parts catalog 7-45
7002-xxx
Assembly 27: Cabling diagram 4—model X642e
7-46 Service Manual
Assembly 27: Cabling diagram 4—model X642e
Asm-
Index
Part number
27—1 40X3309
Units/ mach
1
2
3
4
40X0162
40X0163
40X0226
1
1
1
Units/ kit or pkg
1
1
1
1
Description
Upper front cover hinge assembly—X642e, includes
• 1A—Operator panel to LCD Inverter card cable (2-pin)
• 1B—Operator panel card to UICC #2 card cable (8-pin)
• 1C—USB cable (1)
• 1D—Cover open switch/cable from system board
• 1E—LCD display to operator panel card cable (14-pin ribbon)
• 1F—Operator panel cable from SCC
• 1G—Operator panel card to bezel card cable (4-pin)
• 1H—LCD display to operator panel card cable (4-pin)
• 1J—LCD display to LCD inverter card cable (2-pin)
System board to fuser board cable assembly
Fuser AC lamp to LVPS cable assembly
Fuser connector (fuser AC to fuser lamp)
7002-xxx
Parts catalog 7-47
7002-xxx
Assembly 28: Cabling diagram 4—models X644e/X646e
7-48 Service Manual
7002-xxx
Assembly 28: Cabling diagram 4—models X644e/X646e
Asm-
Index
Part number
28—1 40X0515
Units/ mach
1
2
3
4
5
6
40X0511
40X0512
40X0162
40X0163
40X0226
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
Description
Upper front cover hinge assembly—X644e/X646e, includes:
• 1A—USB cable (1)
• 1B—Cover open switch/cable (1)
• 1C—Operator panel cable to SCC card (1)
See full description of upper front cover hinge assembly on
Inverter 32-pin cable (operator panel card to LCD inverter card)
32-pin cable (LCD display to operator panel cable)
System board to fuser board cable assembly
Fuser AC lamp to LVPS cable assembly
Fuser connector (fuser AC to fuser lamp)
Parts catalog 7-49
7002-xxx
Assembly 29: Cabling diagram 5
3
3
1
2
3
4
5
7-50 Service Manual
Assembly 29: Cabling diagram 5
Asm-
Index
Part number
29—1 40X0310
2 40X0159
3
4
5
40X0249
40X0054
40X0161
Units/ mach
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
Description
Multipurpose feeder pick arm assembly with solenoid
Main drive motor cable assembly
EP DC fan assembly
Main fan with cable, 500-sheet output
Ground cable
7002-xxx
Parts catalog 7-51
7002-xxx
Assembly 30: Cabling diagram 6—model X642e
7-52 Service Manual
7002-xxx
Assembly 30: Cabling diagram 6—model X642e
Asm-
Index
Part number
30—1 40X0491
Units/ mach
1
2
3
4
5
6
7
8
40X0481
40X0487
40X0507
NA
NA
40X0480
NA
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
Description
Flatbed paper size sensor assembly (3 sensors are included in the assembly, model X642e uses only one)
Parts packet, sensors (home sensor)
Flatbed CCD ribbon cable
Modem 30-pin cable
Flatbed interconnect card (CN1) to SCC card cable (J15) (NOT
AVAILABLE AS A FRU)
Flatbed interconnect card (CN4) to home sensor cable (NOT AVAILABLE
AS A FRU)
Flatbed scan motor, including flatbed scan motor to flatbed interconnect card cable
Flatbed paper size sensor to interconnect card cable (CN3) (NOT
AVAILABLE AS A FRU)
Parts catalog 7-53
7002-xxx
Assembly 31: Cabling diagram 6—models X644e/X646e
7-54 Service Manual
7002-xxx
Assembly 31: Cabling diagram 6—models X644e/X646e
Asm-
Index
Part number
31—1 40X0491
Units/ mach
1
2
6
7
8
3
4
5
9
10
11
NA
40X0481
40X0487
40X0509
40X0510
40X0507
NA
NA
NA
40X0480
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
Description
Flatbed paper size sensor assembly (3 sensors are included in the assembly, model X642e uses only one)
Flatbed paper size sensor cable to flatbed interconnect card (CN3) (NOT
AVAILABLE AS A FRU)
Parts packet, sensors (home sensor)
Flatbed CCD ribbon cable
Hard disk IDE 50-pin cable—X646e
Hard disk 4-pin power cable—X646e
Modem 30-pin cable
Scanner control card (J1) to flatbed interconnect card (CN1) cable (NOT
AVAILABLE AS A FRU)
Scanner control card (J28) to flatbed interconnect card (CN5) (NOT
AVAILABLE AS A FRU)
Home sensor to flatbed interconnect card (Cn4) (NOT AVAILABLE AS A
FRU)
Flatbed scan motor, including scan motor
Parts catalog 7-55
7002-xxx
Assembly 32: Cabling diagram 7
4
3
1A
2
1B
1C
1D
Asm-
Index
Part number
32—1 40X0481
Units/ mach
1
2
3
4
40X0456
40X0486
NA
1
1
1
Units/ kit or pkg
1
1
1
1
Description
Parts packet, sensors
• A—Second scan sensor
• B—Jam access door sensor
• C—First scan sensor
• D—Interval sensor
Pickup arm assembly solenoid
Motor driver card
Paper present sensor cable (NOT AVAILABLE AS A FRU)
7-56 Service Manual
Assembly 33: Cabling diagram 8—model X642e
7002-xxx
Asm-
Index
Part number
33—1 40X0481
Units/ mach
1
2
3
4
5
6
NA
40X0506
NA
N/A
N/A
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
Description
Parts packet, sensors
• A—ADF top cover open sensor
• B—First scan sensor
• C—Flatbed cover closed sensors (cover closing, cover closed)
• D—ADF paper length sensor
Feed motor cable (NOT AVAILABLE AS A FRU)
MDC to flatbed interconnect card 36-pin cable
Flatbed cover open sensor cable (NOT AVAILABLE AS A FRU)
Transport motor cable (NOT AVAILABLE AS A FRU)
Paper length sensor cable, includes paper width sensor assembly—X644e/
X646e
Parts catalog 7-57
7002-xxx
Assembly 34: Cabling diagram 8—models X644e/X646e
Asm-
Index
Part number
34—1 40X0481
Units/ mach
1
4
5
2
3
6
7
NA
40X0502
40X0506
NA
N/A
N/A
1
1
1
1
1
1
1
1
1
1
1
1
Units/ kit or pkg
1
Description
Parts packet, sensors
• A—ADF top cover open sensor
• B—First scan sensor
• C—Flatbed cover closed sensors (cover closing, cover closed)
• D—ADF paper length sensor
Feed motor cable (NOT AVAILABLE AS A FRU)
ADF CCD to flatbed interconnect card 36-pin cable—X644e/X646e
MDC to flatbed interconnect card 36-pin cable
Flatbed cover open sensor cable (NOT AVAILABLE AS A FRU)
Transport motor cable (NOT AVAILABLE AS A FRU)
Paper length sensor cable, includes paper width sensor assembly—X644e/
X646e
7-58 Service Manual
Assembly 35: Optional 250-sheet paper drawer
7002-xxx
Asm-
Index
Part number
6
7
5
5
35—1 40X3230
2
3
4
99A0063
56P4129
8
9
10
11
12
13
14
40X3232
56P1228
99A1929
40X4308
40X3234
40X3233
99A0272
99A0275
40X3237
Units/ option
1
1
1
1
1
2
2
1
1
3
4
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
2
1
1
3
4
1
1
1
1
Description
250-sheet paper drawer, complete assembly
Parts packet, screws (PP 99A0263) (switch spring)
Switch activate spring
Paper out arm—250-sheet
Parts packet, screws (PP 99A0263) (auto comp mounting)
Parts packet, screws (PP 99A0263)
Pick arm assembly
Bellcrank—250-sheet paper tray
Bellcrank spring—250-sheet paper tray
Pick roll assembly
Bin low sensor with cable
Option pass thru sensor
Drive shaft—250-sheet
Power takeoff spring
Base assembly
Parts catalog 7-59
7002-xxx
Assembly 36: Optional 250-sheet paper tray
Asm-
Index
Part number
36—1 40X3231
2 40X3235
3
4
56P1279
56P4230
5
6
7
99A0121
99A0120
40X3236
Units/ option
1
1
1
1
1
1
1
Units/ kit or pkg
1
2
1
4
1
1
1
Description
Tray assembly, option—250-sheet
Side restraint—250-sheet tray
Wear strips
Clip—250 sheet pass thru
Plate—250-sheet tray wear
Restraint pad
Back restraint—250-sheet tray
7-60 Service Manual
Assembly 37: Optional 500-sheet paper drawer
7002-xxx
Asm-
Index
Part number
9
10
11
12
13
14
7
8
5
6
37—1 40X3243
2
3
4
40X3246
56P1228
56P2540
40X4308
40X3233
99A0275
99A0447
40X3234
40X3247
56P4145
99A0063
Units/ option
1
1
1
1
1
1
1
1
1
1
1
1
1
3
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
2
1
1
1
3
Description
Tray and drawer assembly, complete—500-sheet
Parts packet, screws (PP 99A0263) (auto comp mounting screw)
Pick arm assembly—500 sheet
Bellcrank spring arm
Bellcrank spring—500-sheet option tray
Pick roll assembly
Option pass thru sensor
Power takeoff spring
Drive shaft—500-sheet
Bin low sensor with cable
Base assembly, 500-sheet
Paper out arm—500-sheet drawer
Switch activate spring
Parts packet, screws (PP 99A0263)
Parts catalog 7-61
7002-xxx
Assembly 38: Optional 500-sheet paper tray
Asm-
Index
Part number
38—1 40X4663
2
3
4
56P4137
99A0292
56P4196
5
6
7
56P4195
99A0120
56P4147
Units/ option
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
4
1
1
2
1
Description
Tray assembly—500-sheet
Side restraint—500-sheet tray
Wear strips
Pass thru plate
Plate—500 sheet wear
Restraint pad
Back restraint—500-sheet tray
7-62 Service Manual
Assembly 39: Duplex option
7002-xxx
Asm-
Index
Part number
39—1 56P4102
Units/ option
1
Units/ kit or pkg
1
Description
Duplex assembly—500-sheet
Parts catalog 7-63
7002-xxx
Assembly 40: Envelope feeder
1
7-64 Service Manual
Assembly 40: Envelope feeder
Asm-
Index
Part number
40—1 40X3248
Units/ option
1
Units/ kit or pkg
1
Description
Complete envelope option
7002-xxx
Parts catalog 7-65
7002-xxx
Assembly 41: High-capacity feeder 1
7-66 Service Manual
Assembly 41: High capacity feeder 1
Asm-
Index
Part number
6
7
8
9
10
41—1 40X3249
2 99A1818
3
4
5
99A0681
40X3254
56P4157
40X3252
99A0658
Units/ option
4
4
4
1
2
4
1
1
1
1
Units/ kit or pkg
1
1
1
1
2
1
1
2
1
1
Description
Complete option assembly (A4)
Wear dimple strip
Wear strip
Front door assembly
Door hinge
Parts packet, nuts (PP 99A0676) (6-32 hinge mounting nut)
Parts packet, washers (PP 99A0677) (hinge mounting flat washer)
Parts packet, washers (PP 99A0677) (hinge mounting star washer)
2000-sheet option control card assembly
Door magnet
7002-xxx
Parts catalog 7-67
7002-xxx
Assembly 42: High-capacity feeder 2
Asm-
Index
Part number
42—1 99A0654
2
3
4
40X3262
40X2669
Units/ option
1
1
1
Units/ kit or pkg
1
1
1
Description
Paper low switch
Parts packet, nuts (PP 99A0676)
AC external jumper cord
Power supply board
7-68 Service Manual
Assembly 43: High-capacity feeder 3
7002-xxx
Asm-
Index
Part number
43—1 99A0275
2 99A0272
Units/ option
1
1
Units/ kit or pkg
1
1
Description
Power takeoff spring
Drive shaft—250-sheet
Parts catalog 7-69
7002-xxx
Assembly 44: High-capacity feeder 4
Asm-
Index
44—1
2
3
4
Part number
40X3255
40X4308
40X3233
Units/ option
2
1
3
1
Units/ kit or pkg
Description
1
2
1
Parts packet, screws (PP 99A0263) (auto comp assembly mounting screw)
Pick arm assembly—2000-sheet
Pick roll assembly
Option pass thru sensor
7-70 Service Manual
Assembly 45: Options
Asm-
Index
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
NS
Part number
40X1376
40X1377
40X1378
40X1562
40X0291
40X0290
40X2529
56P4116
40X3478
40X4179
40X1513
40X1514
40X1508
40X1509
40X1510
40X1564
40X1455
40X3477
40X4181
40X3479
40X4178
40X4180
40X1515
40X1512
40X0179
7375947
40X0499
Units/ option
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Units/ kit or pkg
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
128MB memory option
256MB memory option
512MB memory option
32MB Flash card
64MB Flash card
Bar code card assembly—X642e
Bar code card assembly—X644e/X646e
PrintCryption card assembly—X642e
PrintCryption card assembly—X644e/X646e
PRESCRIBE card assembly—X644e/X646e
MarkNet 8020 Gigabit Ethernet
MarkNet 8030 Fiber Ethernet
MarkNet 8050 wireless print server, 802.11g, US
MarkNet 8050 wireless print server, 802.11g, non-US
Parallel 1284-B interface card
RS232C serial interface card
IPDS SCS/TNe card assembly—X644e/X646e
Universal adjustable tray assembly—400-sheet
Forms card assembly—X642e
Forms card assembly—X644e/X646e
Simplified Chinese font card
Traditional Chinese font card
Korean font card
Japanese font card
Nyogel 744 grease packet
Relocation kit
Screws, parts packet
7002-xxx
Parts catalog 7-71
7002-xxx
7-72 Service Manual
Index
7002-xxx
Numerics
250-sheet paper drawer, option
250-sheet paper tray, option parts catalog
2 xx
paper jam and paper handing errors 2-57
500-sheet paper drawer, option
500-sheet paper tray
500-sheet paper tray, option parts catalog
80 scheduled maintenance
8 xx Service error codes
900.xx error code service check
950.00 through 950.29 EPROM mismatch failure
950.30 through 950.60 EPROM mismatch failure
9 xx Service error codes
A
adjustments fuser solenoid
paper alignment assembly
printhead assembly
scanner registration
alignment assembly
parts catalog
autocompensator, integrated tray parts catalog
pick roll installation
autoconnect connectors, bottom 5-8
autoconnect connectors, front
automatic document feeder (ADF) parts catalog
,
sensor locations
B barcode, system board
bevel gear
blower duct
Button Test
buttons accessing service menus
Button Test
upper front cover including buttons
upper front panel button kit
C
,
,
,
CACHE Test
Configuration ID
configuration menu
Automatic Scanner Registration
available menus
Disk Encryption
Energy Conserve
EVENT LOG (print only)
Factory Defaults
FB Edge Erase
Font Sharpening
Jobs On Disk
LES Applications
Min Copy Memory
Panel Menus
PPDS Emulation
Print Quality Pages
Require Standby
Reset Maintenance Counter
SIZE SENSING
Wipe Disk
Wiper Message
configurations, models
,
,
connector locations
autoconnect—bottom 5-8 autoconnect—front 5-8
connectors flatbed interconnect card
fuser board
high voltage power supply (HVPS)
LCD inverter board (IUCC #2)
low voltage power supply (LVPS)
modem card
operator panel card (UICC #1)—model X642e
operator panel card (UICC #1)—models X644e/X646e
scanner control card
USB card
Index I-1
7002-xxx contrast control
cover closed switch
D defaults
EP defaults
factory defaults
US/Non-US defaults
deflector inner paper deflector assembly
MPF lower paper deflector 4-117
upper paper deflector assembly
developer drive assembly
developer drive coupler kit
diagnostics menu
available tests
BASE SENSOR TEST
DEVICE TESTS
Disk Test/Clean
Flash Test
DUPLEX TESTS
Duplex Feed 1
Duplex Feed 2
Sensor Test
EP SETUP
Charge Roll
EP Defaults
Fuser Temp
Gap Adjust
Transfer
Warm Up Time
EVENT LOG
Display Log
Print Log
HARDWARE TESTS
Button Test
CACHE Test
DRAM Test
parallel wrap tests
INPUT TRAY TESTS
Feed Test
Sensor Test
OUTPUT BIN TESTS
Feed Test
I-2 Service Manual
PRINT TESTS
Prt Quality Pgs
PRINTER SETUP
Configuration ID
Edge to Edge
engine settings
Envelope Enhance
Model Name
Par x Strobe Adj
Perm Page Count
Serial Number
SCANNER TESTS
Feed Test
Scanner Manual Registration
dimensions
Disk Encryption
DRAM Test
duplex option parts catalog
duplex tests
Duplex Feed 1
Duplex Feed 2
Motor Test
Quick Test
Top Margin
E
Energy Conserve
Envelope Enhance
envelope feeder parts catalog
Envelope Prompts
EP duct
,
error codes, service
ESD cover
ESD-sensitive parts
event log clear log (diagnostics menu)
display log (diagnostics mode)
print log (configuration menu)
print log (diagnostics menu)
F fans
EP fan
flag main fan
,
fuser exit sensor flag and spring 4-83
fuser narrow media flag and spring
paper bin full sensor
Flash Test
flatbed interconnect card
parts catalog
flatbed scanner parts catalog
,
sensor locations
flatbed white cushion, removal
frame extensions
frames, parts catalog
fuser
parts catalog
fuser board
fuser cover
fuser exit sensor flag and spring removal
parts catalog
fuser lamp parts catalog
fuser narrow media sensor flag and spring
flag and spring parts catalog
flag and spring removal
parts catalog
fuser solenoid
fuser to LVPS AC cable removal
fuser transfer plate removal
fuser wiper cover assembly parts catalog
,
G gap adjustment
,
gear release link removal
7002-xxx
H handle
hard disk parts catalog
Help button, service check
high voltage power supply (HVPS)
parts catalog
high-capacity feeder
high-capacity input tray (HCIT) options
parts catalog
,
Home button, service check
Home screen
I
inner paper deflector removal 4-101
inner shield parts catalog
removal—models X644e/X646e
input sensor removal
input sensor tray tests
input source tests
input tray feed test
installation
fuser assembly
fuser exit sensor spring
fuser narrow media sensor
fuser narrow media spring replacement
pick roll assembly (integrated tray autocompensator)
integrated tray autocompensator assembly parts catalog
interface card
parts catalog
J jams paper path
Jobs On Disk
K
Key Repeat Initial Delay
Key Repeat Rate
Index I-3
7002-xxx
L lamp, fuser
LCD inverter board
left cover handle holder removal 4-72
Lexmark Embedded Solution
locations
ADF sensors
flatbed sensors
low voltage power supply (LVPS)
parts catalog
lower front cover assembly removal
lower paper deflector, MPF
lubrication specifications
M main drive assembly parts catalog
main fan removal
maintenance
ESD-sensitive parts
lubrication
maintenance kit
6-1 preventive 6-1 safety inspection guide 6-1
maintenance approach
maintenance kits
media specifications
Menu button, service check
accessing service menus
configuration menu
diagnostics menu
list of user menus
messages
check device connection messages 2-56
service error codes
user attendance messages
user line 2 link messages
user status displays
Model Name
models
X642e cabling diagram—parts catalog
operator panel
X644e/X646e cabling diagram—parts catalog
operator panel
I-4 Service Manual modem card connectors
parts catalog
motor driver board, connectors 5-23
MPF arm assembly
MPF lower paper deflector
MPF solenoid assembly
multipurpose feeder parts catalog
N narrow media sensor
fuser narrow media sensor numeric keypad
O operator panel
Button Test
LCD inverter board
operator panel card (UICC #1), model X642e
operator panel card, models X644e/X646e
Panel Test
right cover assembly service check 2-154
upper front cover
USB card
options
parts catalog
service checks
outer shield parts catalog
P packaging
page count
Fuser Page Count
Page Count 3-18 permanent page count 3-18
Panel Menus
Panel Test
paper bin full sensor flag 4-124
paper deflector assembly
upper
paper feed jams
200 and 201—remove cartridge
202—open rear door
23x and 24x jams
23x—duplex rear door
250—MPF
260—envelope feeder
290, 291, 292, and 294 scanner jams
access door and trays
access doors and trays
paper path
paper jam error codes
paper path
Paper Prompts
paper size sensing board
paper specifications
parts catalog
250-sheet paper drawer, option
250-sheet paper tray, option
500-sheet paper drawer, option
500-sheet paper tray, option
cabling
,
,
,
covers—printer
covers—printer—model X642e
covers—printer—model X644e/X646e
drives—main drive and developer drive
electronics
power supplies
shields
envelope feeder
high-capacity feeder
,
integrated paper tray—500-sheet 7-30
optional 250-sheet paper drawer 7-59
optional 250-sheet paper tray
options
paper feed
autocompensator
scanner ADF—lower exit guide assembly
scanner ADF—motors and belts
scanner ADF—paper feed
scanner ADF—pickup
scanner ADF—sensors
pass thru plate
pick rolls, integrated tray autocompensator
pick tire integrated tray autocompensator pick roll
MPF
power takeoff shaft and spring
PPDS Emulation
preventive maintenance
print quality pages
print registration
7002-xxx printhead
parts catalog
Q quality printer
banding
2-163 black bands on outer edges 2-163
blank page
blurred or fuzzy print
light print
random marks
residual image
toner on backside of printed page 2-164
scanner
line compression
vertical streaks or lines 2-165
quality pages
Quick Disk Test
Quick Test
R redrive assembly parts catalog
redrive door
REGISTRATION
registration
Scanner
Automatic Registration
Scanner Manual Registration 4-5
relocation kit
removal procedures and cautions
removals printer removals bevel gear
developer drive assembly
developer drive coupler kit
fuser assembly
fuser exit sensor
fuser exit sensor flag and spring
fuser lamp
fuser narrow media flag and spring
fuser narrow media sensor
fuser to LVPS AC cable
fuser transfer plate
fuser wiper cover assembly
gear release link
high voltage power supply
Index I-5
7002-xxx
inner paper deflector assembly 4-101
inner shield—model X642e
inner shield—models X644e/X646e
integrated tray autocompensator assembly
integrated tray autocompensator pick roll assembly
LCD inverter card assembly
LCD touchscreen—model X642e
LCD touchscreen—models X644e/X646e 4-67
left and right frame extensions
left cover handle holder
low voltage power supply (LVPS)
lower front cover assembly 4-71
lower paper deflector
main drive assembly
main fan
MPF arm assembly
MPF pick tire removal
MPF solenoid assembly
MPF⁄lower front cover assembly
operator panel left cover assembly
operator panel right cover assembly 4-64
paper alignment assembly
paper bin full sensor flag
paper size sensing board
pass thru plate
power takeoff shaft and spring
printer left side cover
redrive assembly
redrive door
right cover handle holder
right cover removal
signature button contact assembly
system board and inner shield—model X642e
system board and inner shield—models X644e/
X646e
toner sensor
transfer roll assembly
upper front cover hinge assembly
upper paper deflector assembly
upper sub cover
upper tray cover
upper tray cover (paper support) 4-56
USB card
scanner ADF and flatbed
ADF attach screws
ADF CCD module assembly
ADF complete assembly
ADF front cover
ADF pick assembly
ADF top cover
ADF upper entrance guide assembly
CCD belt tension spring
CCD beth removal
flatbed CCD module assembly
flatbed CCD ribbon cable
flatbed contact glass
flatbed interconnect card removal
flatbed paper length sensor assembly
flatbed scan motor assembly
flatbed white cushion
front flatbed cover
hard disk
home sensor
lower exit guide assembly 4-47
pickup solenoid assembly
scan cover (flatbed) removal
scanner control card
scanner flatbed glass holder assembly
scanner left side cover
scanner right side cover
separator assembly torque limiter
upper glass holder
Require Standby
right cover handle holder removal
S safety information
safety inspection guide
scanner parts catalog
,
,
,
Scanner Automatic Registration 4-4
scanner control card
Scanner Manual Registration 3-23
scheduled maintenance
sensors
flatbed paper length sensor assembly 4-35
fuser narrow media sensor
input
,
output bin sensor, integrated paper tray
paper bin full
paper size sensing board
parts catalog (scanner)
toner
I-6 Service Manual
7002-xxx service checks
202.03 error code
202.06 error code
290.00 error code
290.01 error check
290.02 error code
290.10 error code
291.00 error code
291.01 error code
291.02 error code
292.00 error code
293 error code
294.00 error code
294.01 error code
294.02 error code
294.03 error code
298.01 error code
298.02 error code
845.00 error code
848.00 error code
848.01 error code
900.90 error code
950.00 through 950.29 EPROM mismatch failure
ADF paper length
cover closed sensors—flatbed
cover open switch/cable—printer
dead machine
DRAM memory options
envelope feeder
flash memory option
flatbed size sensor
fuser exit sensor
fuser narrow media sensor
fuser solenoid
hard disk option
high-capacity feeder input tray
hot fuser
,
input sensor
LCD touchscreen contrast control—model X642e
LCD touchscreen display—models X644e/X646e
main fan
network card (976.xx)
network card (977.xx)
operator panel Help and Home buttons—model X642e
2-154 operator panel Menu button—X642e 2-154
operator panel right cover assembly
options
output bin sensor
paper feed
paper size sensing board
paper width sensor—model X644e/X646e
parallel port
print quality
printhead
signature button assembly
transfer roll
shield inner shield—model X642e
inner shield—models X644e/X646e
outer
signature button contact assembly
specifications
data streams
dimensions
memory configuration
operating clearances
resolution
start
strobe adjustment
sub error codes
symptoms
envelope feeder
high-capacity feeder
paper trays
printer (MFP)
scanner—ADF symptoms
scanner—scan quality
system board barcode
parts catalog
removal—models X644e/X646e
Index I-7
7002-xxx
T theory of operation autocompensator
autoconnect cabling and connectors
option microcode
Top Margin duplex
simplex (front side)
service check—model X642e
2-149 service check—models X644e/X646e 2-149
transfer roll assembly parts catalog
U
UICC #1
model X642e operator panel card 2-149 ,
model X644e/X646e operator panel card
UICC #2
LCD inverter board
upper front cover hinge assembly removal
upper paper deflector
upper sub cover, removal
upper tray cover removal
USB card connectors
location
user attendance messages
user line 2 link messages
user status displays
W warm up time
Wipe Disk
wiper cover
wrap tests
I-8 Service Manual
Part number index
7002-xxx
P/N Description Page
40X0079
40X0084
40X0085
40X0086
40X0098
40X0099
40X0100
40X0101
40X0103
40X0105
40X0106
40X0107
40X0058
40X0059
40X0060
40X0061
40X0062
40X0065
40X0066
40X0069
40X0072
40X0074
40X0076
40X0077
40X0040
40X0042
40X0043
40X0044
40X0045
40X0046
40X0048
40X0049
40X0050
40X0051
40X0052
40X0054
1319128
40X0001
40X0009
40X0021
40X0024
40X0025
40X0026
40X0027
40X0028
40X0030
40X0032
40X0033
40X0034
40X0036
40X0039
Parallel wrap plug
Fuser wiper cover assembly
TLI/ID/serial number label—blank
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Cartridge holddown spring
Right frame extension
Left frame extension
Contact, RSF ground
Upper redrive deflector
Upper diverter spring
Redrive assembly, 500 in/500 out
Transfer deflector with brush
Machine mounting pad
Signature button contact assembly with cable
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Toner sensor assembly
Developer support roller
Upper paper feed deflector
Inner paper feed deflector
Input sensor
Gear guard
ESD shield with label
Paper size sensing board assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-13
Paper switch activate spring
Gear release link
Counterbalance spring
Standard bin level sensor
Standard bin level sensor bracket
Main fan with cable, 500-sheet output
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Output paper level flag
Extension guide
External ground clip
Laser printhead cable assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24
Printhead assembly (includes all cables)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24
Frame extension, nut plate
Pick arm assembly—500-sheet
Parts packet, bellcrank assembly for—500-sheet tray
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
Paper out flag—500-sheet tray
Paper size/autocompensator cable
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
Pick roll assembly
Multipurpose feeder paper out flag
Multipurpose feeder lower deflector assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Paper feed alignment assembly paper feed
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Reference ground clip
Parts packet (reference adjust)
Tray assembly—500-sheet tray
Side restraint
115 V Maintenance kit
220 V Maintenance kit
Pass thru plate—500-sheet tray
Restraint pad
Back restraint
Gearbox with motor
Part number index I-9
7002-xxx
40X0197
40X0207
40X0208
40X0209
40X0213
40X0215
40X0223
40X0225
40X0226
40X0227
40X0229
40X0230
40X0153
40X0156
40X0159
40X0160
40X0161
40X0162
40X0163
40X0165
40X0174
40X0179
40X0182
40X0183
40X0231
40X0232
40X0236
40X0238
40X0239
40X0249
40X0254
40X0255
40X0256
40X0257
40X0258
40X0260
40X0111
40X0112
40X0114
40X0115
40X0120
40X0121
40X0122
40X0123
40X0124
40X0125
40X0126
40X0127
40X0129
40X0130
40X0131
40X0132
40X0133
40X0134
40X0135
40X0149
40X0150
40X0151
40X0152
Power takeoff shaft—500-sheet
Power takeoff shaft spring
Developer drive assembly
Parts packet, developer drive
Fuser wiper cavity cover
Fuser cover assembly kit
Fuser lamp, 115V
Fuser lamp, 220V
Narrow media sensor
Exit sensor
Parts kit, charge roll link asm, left side
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
Charge roll assembly
Parts kit, right side charge roll link assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
Transfer roll assembly
Transfer roll assembly right arm
Transfer roll right spring
Transfer pivot shaft
Transfer roll left spring
Transfer roll left arm
Inner shield assembly
Outer shield
USB board assembly
Ethernet shield (blank)
INA flat cover (blank)
Bottom/front autoconnect cable assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45
Main drive motor cable assembly
MPF sensor cable
Ground cable
System board to fuser board cable assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47
Fuser AC lamp to LVPS cable assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47
Parts packet
- - - - - - - - - - - - - - - 7-11
,
,
Parts packet (cable ties)
Nyogel 744 grease packet
Wear strip
Plate, 500-sheet tray wear
100 V Maintenance kit
EP duct
Blower duct
Gear #60 MPF shield
Tray bias assembly
Paper low/out sensor card assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
HVPS/input sensor/toner sensor cable assembly
- - - - - - - - - - - - - - - - - - - - - - - - - 7-15
,
Right side hand holder
Fuser AC to fuser lamp cable
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
Parts packet (fuser mounting screw)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
Narrow media sensor cable
Exit sensor cable
Left side hand holder
Redrive door assembly 500 sheet
Exit/narrow media sensor cover
Narrow media flag/spring kit
Exit sensor flag/spring kit
EP DC fan assembly
Parts packet, redrive mounting screws
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Power cord set (8 ft right angle)—Argentina
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
Power cord set (8 ft right angle)—Bolivia and Peru
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
Power cord set (8 ft right angle)—Chile, Uruguay
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
Power cord set (8 ft right angle)
Power cord set (8 ft right angle, 13 amp)—United States
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
I-10 Service Manual
7002-xxx
40X0471
40X0472
40X0473
40X0474
40X0475
40X0476
40X0478
40X0479
40X0480
40X0481
40X0482
40X0483
40X0458
40X0460
40X0461
40X0462
40X0463
40X0464
40X0465
40X0466
40X0467
40X0468
40X0469
40X0470
40X0484
40X0485
40X0486
40X0487
40X0489
40X0490
40X0491
40X0493
40X0494
40X0495
40X0496
40X0497
40X0264
40X0271
40X0272
40X0280
40X0281
40X0285
40X0290
40X0291
40X0293
40X0294
40X0295
40X0301
40X0303
40X0304
40X0305
40X0306
40X0310
40X0450
40X0451
40X0452
40X0453
40X0456
40X0457
Standard bin level sensor cable
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Power cord set—Hong Kong
Power cord set (8 ft right angle)—Japan
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
Power cord set (6 ft straight)—Korea
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
Power cord set—Taiwan
Frame clip
RS232C serial interface card
Parallel 1284-B interface card
Power cord set (8 ft right angle)—UK
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
Power cord set—Denmark, Norway, and Sweden
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
Power cord set—Israel
Power cord set—AS/NZ
Power cord set—PRC
Power cord set—Botswana, Lesotho, Namibia, Pakistan, and South Africa
- - - - - - - - - - - - - - - - - - - - 7-39
Power cord set—Switzerland
High voltage contact kit
Multipurpose feeder pick arm assembly with solenoid
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-27
Complete ADF assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Document tray assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
ADF top cover assembly
Pickup assembly
Pickup arm assembly solenoid
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Complete flatbed scanner assembly—X644e/X644e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
ADF CCD module assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-18
Lower exit guide assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-18
Feed motor (ADF feed)
ADF scan motor assembly
ADF scan cover
ADF front cover
ADF rear cover
Flatbed white cushion
Upper cover assembly
Upper tray cover (paper support)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Upper sub cover assembly
Left cover assembly
Right cover assembly
Left side cover
Right side cover
Front cover
Scan cover
Cover bezel with Lexmark logo—X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Flatbed CCD module assembly
Flatbed CCD drive belt
Flatbed scan motor, including flatbed scan motor to flatbed interconnect card cable
Parts packet, sensors
- - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
,
Belts
Flatbed contact glass
Glass holder assembly
Flatbed interconnect card assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
Motor driver card
Flatbed CCD ribbon cable
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
Hard disk assembly—X646e
Belt tension spring
Flatbed paper size sensor assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
Multipurpose tray assembly
LCD touchscreen display assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Operator panel left cover assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Operator panel right cover assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
LCD touchscreen inverter card
Part number index I-11
7002-xxx
40X3230
40X3231
40X3232
40X3233
40X3234
40X3235
40X3236
40X3237
40X3243
40X3244
40X3245
40X3246
40X1514
40X1515
40X1562
40X1564
40X2529
40X2590
40X2591
40X2592
40X2669
40X2722
40X2792
40X2793
40X3247
40X3248
40X3249
40X3252
40X3254
40X3255
40X3262
40X3296
40X3297
40X3298
40X3299
40X3301
40X0498
40X0502
40X0506
40X0507
40X0509
40X0510
40X0511
40X0512
40X0513
40X0514
40X0515
40X0516
40X0519
40X0520
40X1376
40X1377
40X1378
40X1455
40X1508
40X1509
40X1510
40X1512
40X1513
Scanner control card—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
ADF CCD to flatbed interconnect card 36-pin cable—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - 7-58
MDC to flatbed interconnect card 36-pin cable
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
Modem 30-pin cable
Hard disk IDE 50-pin cable—X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
Hard disk 4-pin power cable—X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
Inverter 32-pin cable
32-pin cable
Flatbed cover closed actuator
Flatbed cover closing actuator
Upper front cover hinge assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Counterbalance spring
Modem card assembly
Interface card assembly
MarkNet 8020 Gigabit Ethernet
MarkNet 8030 Fiber Ethernet
MarkNet 8050 wireless, US
64MB Flash card
128MB memory option
256MB memory option
512MB memory option
Japanese font card
Simplified Chinese font card
Traditional Chinese font card
Korean font card
MarkNet 8050 wireless, non-US
32MB Flash card
IPDS SCS/TNe card assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
Fuser assembly w/220 V lamp
Fuser assembly w/100 V lamp
Fuser assembly w/115 V lamp
Power supply board
System board assembly (network), (Board ID Q0016000)—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - 7-41
Bar code card assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
PRESCRIBE card assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
250-sheet paper drawer, complete assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59
Tray assembly, option—250-sheet
Pick arm assembly
Option pass thru sensor
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59
Bin low sensor with cable
Side restraint—250-sheet tray
Back restraint—250-sheet tray
Base assembly
Tray and drawer assembly, complete—500-sheet
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61
LVPS/AIO—115 V ac
LVPS/AIO—220 V ac
Pick arm assembly—500 sheet
Base assembly, 500-sheet
Complete envelope option
Complete option assembly (A4)
2000-sheet option control card assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-67
Front door assembly
Pick arm assembly—2000-sheet
AC external jumper cord
Complete ADF assembly—X642e
Document tray assembly—X642e
Complete flatbed scanner assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
Cover bezel with Lexmark logo—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
LCD mono touchscreen display assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
I-12 Service Manual
7002-xxx
56P4230
7375947
99A0063
99A0120
99A0121
99A0263
99A0272
99A0275
99A0292
99A0447
99A0654
99A0658
56P1228
56P1279
56P2540
56P4102
56P4116
56P4129
56P4137
56P4145
56P4147
56P4157
56P4195
56P4196
99A0676
99A0677
99A0681
99A0954
99A1818
99A1929
40X3302
40X3303
40X3304
40X3305
40X3309
40X3310
40X3311
40X3312
40X3313
40X3477
40X3478
40X3479
40X4178
40X4179
40X4180
40X4181
40X4275
40X4308
40X4596
40X4656
40X4663
40X5224
56P1228
Operator panel left cover assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Operator panel right cover assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
LCD (mono) touchscreen inverter card—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Scanner control card—X642e
Upper front cover hinge assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-3
System board assembly—X642e
Lower exit guide assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-18
Flatbed interconnect card assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
Cover bezel with Lexmark logo—X644e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Bar code card assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
Forms card assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
PrintCryption card assembly—X642e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
PrintCryption card assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
Forms card assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
PRESCRIBE card assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71
Bar code card assembly—X644e/X646e
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71
High voltage power supply
Pick roll assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
,
Power cord set (6 ft right angle)—Brazil
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39
Upper entrance guide kit
Tray assembly—500-sheet
LVPS to system board cable assembly
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45
Bellcrank spring arm
Bellcrank—250-sheet paper tray
Wear strips
Bellcrank spring—500-sheet option tray
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61
Duplex assembly—500-sheet
Universal adjustable tray assembly—400-sheet
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-71
Paper out arm—250-sheet
Side restraint—500-sheet tray
Paper out arm—500-sheet drawer
Back restraint—500-sheet tray
Door hinge
Plate—500 sheet wear
Pass thru plate
Clip—250 sheet pass thru
Relocation kit
Switch activate spring
Restraint pad
Plate—250-sheet tray wear
Parts packet, screws
Drive shaft—250-sheet
Power takeoff spring
Wear strips
Drive shaft—500-sheet
Paper low switch
Door magnet
Parts packet, nuts
Parts packet, washers
Wear strip
Bevel gear with grease packet and washer
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
Wear dimple strip
Bellcrank spring—250-sheet paper tray
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59
Part number index I-13
7002-xxx
I-14 Service Manual
Lexmark X644e, X646e
Wiring diagram
AIO—printer
Lexmark X642e
Wiring diagram
AIO—scanner
Lexmark X644e, X646e
Wiring diagram
AIO—scanner
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