Lexmark MX910de User manual

MX91x and XM91x5
7421-036, -039, -236, -239, -436, -439
Service Manual
•Start diagnostics
•Maintenance
•Safety and notices
•Trademarks
•Index
September 04, 2014 www.lexmark.com
P/N 12G3391

Product information
Product name:
Lexmark MX91x and XM91x5
Machine type:
7421
Model(s):
036, 039, 236, 239, 436, 439
Edition notice
September 04, 2014
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.
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all
countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product,
program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual
property right may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services,
except those expressly designated by the manufacturer, are the user’s responsibility.
Trademarks
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other
countries.
PCL® is a registered trademark of the Hewlett-Packard Company.
All other trademarks are the property of their respective owners.
© 2014 Lexmark International, Inc.
All rights reserved.
P/N 12G3391
7421

Table of contents
Product information.....................................................................................2
Edition notice...............................................................................................2
Notices and safety information..................................................................21
Laser notices............................................................................................................................................21
Safety information...................................................................................................................................24
Preface.......................................................................................................27
Service manual conventions....................................................................................................................27
Change history.........................................................................................................................................27
General information...................................................................................31
Paper and specialty media guide.............................................................................................................31
Using specialty media .......................................................................................................................................31
Paper guidelines ...............................................................................................................................................33
Supported paper sizes, types, and weights ......................................................................................................37
Data security notice.................................................................................................................................42
Tools required for service........................................................................................................................43
Diagnostic information...............................................................................45
Troubleshooting overview.......................................................................................................................45
Performing the initial troubleshooting check ...................................................................................................45
Fixing print quality issues........................................................................................................................45
Initial print quality check ..................................................................................................................................46
Gray background check ....................................................................................................................................46
Blank pages check .............................................................................................................................................49
Solid black pages check.....................................................................................................................................50
Shadow images check .......................................................................................................................................52
Skewed print check...........................................................................................................................................54
Streaked horizontal or vertical lines check ....................................................................................................... 55
Toner smear check............................................................................................................................................57
Toner specks check ...........................................................................................................................................58
Fixing image quality issues......................................................................................................................59
Initial image quality check ................................................................................................................................59
Flatbed scanner image quality check................................................................................................................60
Paper jams...............................................................................................................................................61
Avoiding jams....................................................................................................................................................62
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Understanding jam messages and locations.....................................................................................................62
200 paper jams .................................................................................................................................................64
202 paper jams .................................................................................................................................................71
23y paper jams .................................................................................................................................................79
241–242 paper jams .........................................................................................................................................82
243–245 paper jams .........................................................................................................................................93
28y paper jams ...............................................................................................................................................107
Understanding the printer messages....................................................................................................119
Cartridge low [88.xy].......................................................................................................................................119
Cartridge nearly low [88.xy]............................................................................................................................ 119
Cartridge very low [88.xy]...............................................................................................................................119
Change [paper source] to [custom string] load [orientation].........................................................................119
Change [paper source] to [custom type name] load [orientation]................................................................. 119
Change [paper source] to [paper size] load [orientation] ..............................................................................119
Change [paper source] to [paper type] [paper size] load [orientation]..........................................................120
Close door [x]..................................................................................................................................................120
Complex page, some data may not have printed [39]....................................................................................120
Configuration change, some held jobs were not restored [57] ......................................................................120
Defective flash detected [51]..........................................................................................................................120
Disk full [62] ....................................................................................................................................................120
Disk full, scan job canceled .............................................................................................................................121
Disk must be formatted for use in this device ................................................................................................121
Disk near full. Securely clearing disk space.....................................................................................................121
Empty the hole punch box ..............................................................................................................................121
Error reading USB drive. Remove USB. ...........................................................................................................121
Error reading USB hub. Remove hub. .............................................................................................................121
Fax memory full ..............................................................................................................................................121
Fax partition inoperative. Contact system administrator...............................................................................122
Fax server 'To Format' not set up. Contact system administrator..................................................................122
Fax Station Name not set up. Contact system administrator. ........................................................................122
Fax Station Number not set up. Contact system administrator. ....................................................................122
Incorrect paper size, open [paper source] [34] ..............................................................................................122
Insert hole punch box .....................................................................................................................................122
Insert Tray [x]..................................................................................................................................................123
Insufficient memory for Flash Memory Defragment operation [37] .............................................................. 123
Insufficient memory to collate job [37] ..........................................................................................................123
Insufficient memory to support Resource Save feature [35].......................................................................... 123
Insufficient memory, some Held Jobs were deleted [37] ...............................................................................123
Insufficient memory, some held jobs will not be restored [37]......................................................................123
Insufficient space between paper stacks in Tray 3 .........................................................................................123
Load [paper source] with [custom string] [paper orientation] .......................................................................124
Load [paper source] with [custom type name] [paper orientation] ...............................................................124
Load [paper source] with [paper size] [paper orientation].............................................................................124
Load [paper source] with [paper type] [paper size] [paper orientation]........................................................124
Load Multipurpose Feeder with [custom string] [paper orientation].............................................................124
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Load Multipurpose Feeder with [custom type name] [paper orientation] ....................................................125
Load Multipurpose Feeder with [paper size] [paper orientation] ..................................................................125
Load Multipurpose Feeder with [paper type] [paper size] [paper orientation] .............................................125
Load staples ....................................................................................................................................................125
Load staples [G11, G12]..................................................................................................................................126
[x] maintenance kit very low [80.xy]...............................................................................................................126
Memory full [38] .............................................................................................................................................126
Memory full, cannot print faxes .....................................................................................................................126
Memory full, cannot send faxes .....................................................................................................................126
No analog phone line connected to modem, fax is disabled..........................................................................126
Network [x] software error [54] .....................................................................................................................126
Not enough free space in flash memory for resources [52] ...........................................................................127
Open door H and remove paper from beneath area H10 ..............................................................................127
Paper changes needed....................................................................................................................................127
Parallel port [x] disabled [56]..........................................................................................................................127
Photoconductor low [84.xy] ...........................................................................................................................127
Photoconductor very low [84.xy]....................................................................................................................127
Printer had to restart. Last job may be incomplete........................................................................................127
Reinstall missing or unresponsive cartridge [31.xy] .......................................................................................128
Reinstall missing or unresponsive photoconductor [31.xy]............................................................................128
Remove defective disk [61].............................................................................................................................128
Remove packaging material, [area name] ......................................................................................................128
Remove packaging material, open door C, remove metal clips, remove all screws from scanner carriage...128
Remove paper from all bins............................................................................................................................128
Remove paper from bin [x] .............................................................................................................................128
Remove paper from [linked set bin name] .....................................................................................................129
Remove paper from standard output bin.......................................................................................................129
Replace all originals if restarting job...............................................................................................................129
Replace cartridge, 0 estimated pages remain [88.xy].....................................................................................129
Replace cartridge, printer region mismatch [42.xy] .......................................................................................129
Replace jammed originals if restarting job .....................................................................................................130
Replace [x] maintenance kit, 0 estimated pages remain [80.xy] ....................................................................130
Replace missing photoconductor [31.xy]........................................................................................................130
Replace missing waste toner bottle [82.xy]....................................................................................................130
Replace missing cartridge [31.xy] ...................................................................................................................130
Replace paper pick rollers in [paper source], use parts and instructions in tray 1 or tray 2
compartment [80] ......................................................................................................................................130
Replace photoconductor, 0 pages remain [84.xy] ..........................................................................................130
Replace unsupported cartridge [32.xy] ..........................................................................................................131
Replace unsupported photoconductor [32.xy]...............................................................................................131
Replace waste toner bottle [82.xy].................................................................................................................131
Restore held jobs? ..........................................................................................................................................131
Scanner disabled by admin [840.01]...............................................................................................................131
Scanner disabled. Contact system administrator if problem persists. [840.02] .............................................131
Scanner jam, remove jammed originals from the scanner [2yy.xx] ...............................................................131
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Scanner maintenance required, use ADF Kit [80] ...........................................................................................131
Scanner maintenance required soon, use ADF Kit [80] ..................................................................................131
Serial port [x] disabled [56].............................................................................................................................132
Some held jobs were not restored .................................................................................................................132
SMTP server not set up. Contact system administrator. ................................................................................132
Standard network software error [54]............................................................................................................132
Standard USB port disabled [56].....................................................................................................................132
Supply needed to complete job......................................................................................................................132
The device is operating in Safe Mode. Some print options may be disabled or provide unexpected
results.........................................................................................................................................................133
Too many flash options installed [58].............................................................................................................133
Too many trays attached [58].........................................................................................................................133
Tray [x] paper size unsupported .....................................................................................................................133
Unformatted flash detected [53]....................................................................................................................133
Unsupported disk............................................................................................................................................133
Unsupported option in slot [x] [55] ................................................................................................................134
Waste toner bottle nearly full [82.xy].............................................................................................................134
Weblink server not set up. Contact system administrator. ............................................................................134
User attendance messages....................................................................................................................134
User attendance messages (0‑99) ..................................................................................................................134
Cartridge or photoconductor error service check ..........................................................................................135
Mismatched paper size service check.............................................................................................................136
Insufficient memory service check .................................................................................................................137
Complex page service check ...........................................................................................................................137
PPDS font error service check.........................................................................................................................138
Flash memory failure service check................................................................................................................138
Insufficient flash memory service check.........................................................................................................139
Network service check.................................................................................................................................... 140
Unsupported internal option service check....................................................................................................142
Disabled port service check ............................................................................................................................143
Unrestored held jobs service check ................................................................................................................143
Excess options service check ..........................................................................................................................144
Incompatible hardware option service check.................................................................................................145
Hard disk failure service check .......................................................................................................................145
Maintenance kit service check........................................................................................................................146
Printer hardware errors........................................................................................................................146
111 errors .......................................................................................................................................................147
12y errors........................................................................................................................................................148
13y errors........................................................................................................................................................153
153 errors .......................................................................................................................................................156
16y errors........................................................................................................................................................157
171–182 errors ............................................................................................................................................... 163
189 errors .......................................................................................................................................................164
19y errors........................................................................................................................................................166
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600 errors .......................................................................................................................................................180
685 errors .......................................................................................................................................................181
Steps before starting the 9yy service checks ..................................................................................................183
900 errors .......................................................................................................................................................185
911–963 errors ............................................................................................................................................... 190
ADF/scanner hardware errors...............................................................................................................192
800 error messages.........................................................................................................................................192
809 error messages.........................................................................................................................................192
816–824 error messages.................................................................................................................................193
850–891 error messages.................................................................................................................................193
ADF controller board service check ................................................................................................................194
ADF/scanner image controller board service check .......................................................................................195
ADF CIS service check .....................................................................................................................................196
Scanner controller board service check..........................................................................................................197
Scanner CCD service check .............................................................................................................................198
Scanner lamp service check ............................................................................................................................199
Fax error log codes .........................................................................................................................................199
Escalating a fax issue to second‑level support................................................................................................203
Symptoms..............................................................................................................................................204
3000‑sheet tray tray set failure service check ................................................................................................204
Service menus..........................................................................................207
Understanding the printer control panel..............................................................................................207
Using the control panel...................................................................................................................................207
Understanding the colors of the Sleep button and indicator lights................................................................ 207
Understanding the home screen .................................................................................................................... 208
Using the touch-screen buttons .....................................................................................................................210
Menus list..............................................................................................................................................211
Diagnostics Menu..................................................................................................................................212
Entering the Diagnostics menu.......................................................................................................................212
Reset Separator Roll and Pick Assembly Counter ...........................................................................................212
Reset Maintenance Counter ...........................................................................................................................212
Reset Fuser Counter ....................................................................................................................................... 212
REGISTRATION ................................................................................................................................................ 213
SCANNER CALIBRATION ..................................................................................................................................213
PRINT TESTS ....................................................................................................................................................214
Print Quality Pages..........................................................................................................................................214
HARDWARE TESTS ..........................................................................................................................................215
DUPLEX TESTS .................................................................................................................................................216
INPUT TRAY TESTS ..........................................................................................................................................217
OUTPUT BIN TESTS .........................................................................................................................................217
SENSOR TESTS.................................................................................................................................................218
Motor Tests.....................................................................................................................................................219
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DEVICE TESTS ..................................................................................................................................................223
PRINTER SETUP ...............................................................................................................................................224
REPORTS .........................................................................................................................................................226
EVENT LOG......................................................................................................................................................226
SCANNER TESTS ..............................................................................................................................................227
Exit Diags.........................................................................................................................................................228
Configuration Menu..............................................................................................................................229
Entering the Configuration menu ...................................................................................................................229
Hole Punch Configuration...............................................................................................................................229
Reset Maintenance Counter ...........................................................................................................................229
USB Scan to Local............................................................................................................................................229
Print Quality Pages..........................................................................................................................................229
Reports ........................................................................................................................................................... 230
SIZE SENSING ..................................................................................................................................................230
Tray Linking.....................................................................................................................................................230
Panel Menus ................................................................................................................................................... 230
PPDS Emulation ..............................................................................................................................................231
Download Emuls .............................................................................................................................................231
Safe Mode.......................................................................................................................................................231
Energy Conserve .............................................................................................................................................231
Fax Low Power Support ..................................................................................................................................231
Min Copy Memory ..........................................................................................................................................232
NumPad Job Assist..........................................................................................................................................232
Format Fax Storage.........................................................................................................................................232
Fax Storage Location.......................................................................................................................................232
ADF Edge Erase ...............................................................................................................................................232
FB Edge Erase..................................................................................................................................................233
Scanner Manual Registration.......................................................................................................................... 233
Disable Scanner ..............................................................................................................................................233
Paper Prompts ................................................................................................................................................233
Envelope Prompts........................................................................................................................................... 233
Action for Prompts..........................................................................................................................................234
Jobs on Disk ....................................................................................................................................................234
Disk Encryption ...............................................................................................................................................234
Font Sharpening..............................................................................................................................................234
Require Standby..............................................................................................................................................234
UI Automation ................................................................................................................................................235
LES Applications ..............................................................................................................................................235
Key Repeat Initial Delay ..................................................................................................................................235
Key Repeat Rate..............................................................................................................................................235
Clear Supply Usage History .............................................................................................................................235
Clear Custom Status........................................................................................................................................235
USB Speed.......................................................................................................................................................236
Automatically Display Error Screens ............................................................................................................... 236
Restore factory defaults .................................................................................................................................236
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Exit Config .......................................................................................................................................................237
Entering Invalid engine mode................................................................................................................237
Entering Recovery Mode.......................................................................................................................237
Entering Safe Mode (EverReady Mode)................................................................................................238
Accessing the Network SE Menu...........................................................................................................238
Service Engineer menu..........................................................................................................................238
Accessing the Service Engineer (SE) Menu .....................................................................................................238
Service Engineer (SE) Menu ............................................................................................................................238
Fax Service Engineer (SE) Menu......................................................................................................................239
Repair information...................................................................................241
Removal precautions.............................................................................................................................241
Data security notice ........................................................................................................................................241
Handling ESD‑sensitive parts ..........................................................................................................................241
Restoring the printer configuration after replacing the controller board ......................................................242
Restoring solutions, licenses, and configuration settings ...............................................................................245
Updating the printer firmware ......................................................................................................................246
Backing up eSF solutions and settings ............................................................................................................247
Understanding the marked or colored screws ...............................................................................................248
Ribbon cable connectors ................................................................................................................................ 248
Zero Insertion Force (ZIF) connectors ........................................................................................................248
Horizontal top contact connector ..............................................................................................................249
Horizontal bottom contact connector........................................................................................................251
Vertical mount contact connector ............................................................................................................. 253
Horizontal sliding contact connector .........................................................................................................255
Low Insertion Force (LIF) connector...........................................................................................................257
Adjustments..........................................................................................................................................258
ADF height adjustment ................................................................................................................................... 258
ADF registration adjustment...........................................................................................................................259
ADF separator roller pressure adjustment .....................................................................................................260
Flatbed registration adjustment .....................................................................................................................261
Fuser alignment adjustment ...........................................................................................................................262
MPF separator roller pressure adjustment.....................................................................................................263
Pick roller pressure adjustment ...................................................................................................................... 265
Scanner carriage belt adjustment...................................................................................................................267
3000‑sheet tray pick roller pressure adjustment ...........................................................................................268
2500‑sheet tray transfer guide belt adjustment.............................................................................................270
Removal procedures.............................................................................................................................271
Left side removals.................................................................................................................................272
Left cover removal ..........................................................................................................................................272
Rear left cover removal ..................................................................................................................................273
Main power supply shield removal.................................................................................................................273
Main power supply fan removal .....................................................................................................................274
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Main power supply removal ........................................................................................................................... 275
Printhead removal ..........................................................................................................................................275
Printhead relay board removal.......................................................................................................................276
Right side removals...............................................................................................................................278
Port access door removal ...............................................................................................................................278
Fuser removal .................................................................................................................................................279
Induction heater removal ...............................................................................................................................279
Registration transport assembly.....................................................................................................................282
Upper right cover removal..............................................................................................................................283
Redrive belt cover removal.............................................................................................................................283
Redrive belt removal.......................................................................................................................................284
Transfer roller removal ...................................................................................................................................284
Duplex transport assembly removal ...............................................................................................................285
Duplex transport jam removal knob removal.................................................................................................286
Duplex transport diverter assembly removal .................................................................................................287
Sensor (fuser exit) removal.............................................................................................................................288
Fuser exit sensor actuator removal ................................................................................................................288
Sensor (duplex pass through 1) removal ........................................................................................................289
Duplex pass through 1 actuator removal........................................................................................................290
Duplex transport belt removal........................................................................................................................292
Duplex transport gears removal .....................................................................................................................292
Motor (duplex transport) removal..................................................................................................................293
Right door lock removal..................................................................................................................................295
Tray 2 transport guide ....................................................................................................................................296
MPF removal...................................................................................................................................................297
MPF tray removal ...........................................................................................................................................298
Sensor (MPF paper length) removal ...............................................................................................................299
MPF feed clutch removal ................................................................................................................................300
MPF lift plate solenoid removal......................................................................................................................301
MPF gears removal .........................................................................................................................................302
Sensor (MPF lift plate) removal ......................................................................................................................303
Sensor (MPF empty) removal .........................................................................................................................305
MPF feed/separator assembly........................................................................................................................306
MPF lift plate assembly removal.....................................................................................................................308
MPF empty actuator removal......................................................................................................................... 309
Duplex transport guide removal .....................................................................................................................310
Registration unit latch assembly removal....................................................................................................... 310
Right door switch actuator removal ...............................................................................................................312
Right door removal .........................................................................................................................................312
Registration unit assembly removal ...............................................................................................................314
Registration unit sub-assembly removal ........................................................................................................315
Sensor (fusing speed) removal........................................................................................................................317
Fusing speed actuator removal.......................................................................................................................317
Sensor (duplex pass through 2) removal ........................................................................................................318
Registration unit belt removal ........................................................................................................................ 319
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Registration unit gears removal......................................................................................................................320
Registration unit lock removal........................................................................................................................321
Front side removals...............................................................................................................................323
Control panel frame removal..........................................................................................................................323
Control panel board removal..........................................................................................................................325
Touch screen removal.....................................................................................................................................326
Top front door removal .................................................................................................................................. 327
Bottom front door removal ............................................................................................................................327
Front inner cover removal ..............................................................................................................................328
Waste toner door mount removal..................................................................................................................328
Image controller board removal .....................................................................................................................329
Door switch removal.......................................................................................................................................329
Main power switch removal ...........................................................................................................................330
Sensor (top front door) removal.....................................................................................................................331
Motor (toner supply) removal ........................................................................................................................332
Waste toner drive removal .............................................................................................................................333
Sensor (toner cartridge present) removal ......................................................................................................334
Toner agitator removal ...................................................................................................................................335
Developer unit removal ..................................................................................................................................336
Right door switch removal.............................................................................................................................. 338
Speaker cover removal ................................................................................................................................... 338
Speaker removal .............................................................................................................................................340
Control panel removal ....................................................................................................................................341
Rear side removals................................................................................................................................344
Scanner interface cable cover removal ..........................................................................................................344
Controller board access cover removal ..........................................................................................................345
Engine board cover removal ...........................................................................................................................346
Upper rear cover removal...............................................................................................................................346
IHPS shield removal ........................................................................................................................................347
Induction heater magnetic erase board (IHMEB) removal .............................................................................348
Induction heater power supply (IHPS) removal..............................................................................................350
Noise filter board removal..............................................................................................................................350
Expansion controller board removal ..............................................................................................................351
Power‑saving board removal..........................................................................................................................352
Engine controller board removal ....................................................................................................................353
ADF/scanner image controller board removal ...............................................................................................354
Hard drive removal .........................................................................................................................................356
Controller board removal ...............................................................................................................................356
Fax card removal.............................................................................................................................................357
Motor (fuser pressure) removal .....................................................................................................................358
Paper exit fan duct removal............................................................................................................................359
Paper exit fan removal....................................................................................................................................360
IHPS frame removal ........................................................................................................................................360
Fuser power supply fan removal ....................................................................................................................361
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Motor (toner cartridge) removal ....................................................................................................................362
Motor (redrive) removal .................................................................................................................................364
Controller board frame removal.....................................................................................................................365
Controller board fan removal .........................................................................................................................366
Motor (transport) removal ............................................................................................................................. 367
Motor (developer) removal ............................................................................................................................368
High voltage board removal ...........................................................................................................................369
Motor (registration) removal..........................................................................................................................370
Motor (feed) removal .....................................................................................................................................372
Tray 2 transport drive removal .......................................................................................................................373
Motor (tray 2 transport) removal ...................................................................................................................374
Feed drive assembly removal .........................................................................................................................375
Sensor (tray 1 and 2 paper temperature) removal.........................................................................................376
Ozone fan removal..........................................................................................................................................376
Ozone fan duct removal .................................................................................................................................378
Center cable guide bracket removal...............................................................................................................379
Main drive assembly removal.........................................................................................................................379
Toner cartridge drive assembly removal ........................................................................................................382
Duplex transport clutch removal ....................................................................................................................383
Motor (fuser) removal ....................................................................................................................................384
Fuser drive gearbox removal ..........................................................................................................................385
Toner suction fan removal..............................................................................................................................387
Top side removals.................................................................................................................................389
Standard bin base removal .............................................................................................................................389
Transfer belt fan removal ...............................................................................................................................389
Bin side cover removal....................................................................................................................................390
ADF and scanner removals....................................................................................................................391
ADF assembly removal....................................................................................................................................391
ADF CIS assembly removal..............................................................................................................................394
ADF CIS power supply board removal.............................................................................................................396
ADF controller board removal ........................................................................................................................ 396
ADF cushion removal ......................................................................................................................................396
ADF duplex scan glass removal .......................................................................................................................396
ADF fan removal .............................................................................................................................................398
ADF feed and pick roller assembly removal....................................................................................................398
ADF feed roller removal..................................................................................................................................400
ADF front cover removal................................................................................................................................. 402
ADF glass cleaning roller removal ...................................................................................................................403
ADF left hinge removal ...................................................................................................................................406
ADF pick roller removal...................................................................................................................................407
ADF right hinge removal .................................................................................................................................409
ADF rear cover removal ..................................................................................................................................410
ADF registration guide removal ......................................................................................................................410
ADF scan/exit roller belt removal ...................................................................................................................411
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ADF separator pad removal ............................................................................................................................412
ADF separator roller removal .........................................................................................................................412
ADF top cover assembly removal ...................................................................................................................413
ADF top cover removal ...................................................................................................................................413
ADF tray removal ............................................................................................................................................414
ADF tray bottom cover removal .....................................................................................................................415
Sensor (ADF CIS clean) removal ......................................................................................................................415
Sensor (ADF jam access cover) removal ......................................................................................................... 416
Sensor (ADF scan shaft home) removal ..........................................................................................................417
Sensor (ADF top cover open) removal ............................................................................................................418
Sensor (scan glass clean) removal ..................................................................................................................419
Sensor (scanner cover open) removal ............................................................................................................419
Sensor (scanner cover switch) removal ..........................................................................................................420
Sensor (scanner lamp home) removal ............................................................................................................ 421
Sensor (scanner paper length 1) removal.......................................................................................................422
Sensor (scanner paper length 2) removal.......................................................................................................423
Sensors (ADF tray section) removal................................................................................................................424
Sensors (ADF top open cover section) removal..............................................................................................425
Scanner CCD lens assembly removal .............................................................................................................. 426
Scanner controller board removal ..................................................................................................................428
Scanner glass removal ....................................................................................................................................428
Scanner left cover removal .............................................................................................................................429
Scanner rear cover removal............................................................................................................................430
Scanner right cover removal...........................................................................................................................430
Scanner top cover removal.............................................................................................................................430
Motor (ADF CIS clean) removal.......................................................................................................................431
Motor (ADF scan shaft release) removal ........................................................................................................432
Motor (ADF feed) removal..............................................................................................................................433
Motor (ADF scan) removal..............................................................................................................................435
Motor (ADF registration) removal ..................................................................................................................436
Motor (CIS glass clean) removal .....................................................................................................................439
Motor (scanner drive) removal.......................................................................................................................440
Control panel base removal............................................................................................................................440
Control panel bottom cover removal .............................................................................................................442
2500-sheet tray removals......................................................................................................................442
2500-sheet tray caster wheel removal ........................................................................................................... 442
2500-sheet tray controller board removal .....................................................................................................443
2500-sheet tray LED cover removal................................................................................................................444
2500-sheet tray front right cover removal .....................................................................................................444
2500-sheet tray left cover removal ................................................................................................................445
2500-sheet tray lower right cover removal ....................................................................................................445
2500-sheet tray empty LED removal ..............................................................................................................446
2500-sheet tray rear cover removal ...............................................................................................................446
2500-sheet tray rear right cover removal.......................................................................................................447
2500‑sheet tray division board removal.........................................................................................................447
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2500‑sheet tray main tray empty sensor bottom actuator removal..............................................................448
2500‑sheet tray elevator home sensor actuator removal ..............................................................................449
2500‑sheet tray transfer guide stop removal .................................................................................................450
2500‑sheet reserve tray paper limit sensor actuator removal .......................................................................451
2500‑sheet tray vertical media transport guide assembly removal ...............................................................452
2500‑sheet tray transport roller removal .......................................................................................................453
2500-sheet tray jam access cover removal.....................................................................................................454
2500-sheet tray jam access door strap removal.............................................................................................455
2500-sheet tray paper feed assembly removal .............................................................................................. 456
2500-sheet tray pick assembly removal .........................................................................................................456
2500-sheet tray paper stack transfer guide removal......................................................................................457
2500-sheet reserve tray empty sensor actuator removal ..............................................................................459
2500‑sheet tray stopper removal ...................................................................................................................459
Motor (2500‑sheet tray elevator) removal.....................................................................................................460
Motor (2500‑sheet tray feed) removal...........................................................................................................461
Motor (2500‑sheet tray transfer guide) removal ...........................................................................................462
Motor (2500‑sheet tray transport) removal...................................................................................................462
Sensor (2500‑sheet tray jam access door) removal........................................................................................463
Sensor (2500‑sheet paper stack transfer) removal ........................................................................................464
Sensor (2500‑sheet tray elevator home) removal..........................................................................................465
Sensor (2500‑sheet tray main tray empty, bottom) removal.........................................................................465
Sensor (2500‑sheet tray main tray near empty) removal...............................................................................466
Sensor (2500‑sheet tray main tray empty, top) removal ...............................................................................467
Sensor (2500‑sheet tray main tray elevator limit) removal............................................................................467
Sensor (2500‑sheet tray feed) removal ..........................................................................................................468
Sensor (2500‑sheet tray reserve tray empty) removal...................................................................................469
Sensor (2500‑sheet tray reserve tray paper limit) removal............................................................................470
Sensor (2500‑sheet tray transfer guide home) removal.................................................................................470
Sensor (2500-sheet tray set) removal.............................................................................................................471
Sensor (2500‑sheet tray transport) removal .................................................................................................. 472
2 x 500-sheet tray removals..................................................................................................................473
Sensor (2 x 500-sheet tray jam access door) removal ....................................................................................473
2 x 500-sheet tray caster wheel removal........................................................................................................474
Printer rubber stopper removal......................................................................................................................474
Tray insert paper length guide removal..........................................................................................................475
Tray lock removal............................................................................................................................................477
2 x 500-sheet tray rollers removal..................................................................................................................479
Sensor (2 x 500-sheet tray paper length) removal .........................................................................................479
2 x 500-sheet tray left cover removal.............................................................................................................481
2 x 500-sheet tray empty LED cover removal .................................................................................................481
2 x 500-sheet tray empty LED removal...........................................................................................................482
2 x 500-sheet tray empty LED mount removal ...............................................................................................482
2 x 500-sheet tray rear cover removal............................................................................................................483
Motor (2 x 500-sheet tray lift) removal ..........................................................................................................483
Sensor (2 x 500-sheet tray near empty) removal ...........................................................................................484
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Sensor (2 x 500-sheet tray paper width) removal ..........................................................................................485
2 x 500-sheet tray feed and transport motors removal .................................................................................486
2 x 500-sheet tray controller board removal..................................................................................................487
2 x 500-sheet tray jam access door removal ..................................................................................................488
2 x 500-sheet tray rear right cover removal ...................................................................................................489
2 x 500-sheet tray bottom right cover removal..............................................................................................490
2 x 500-sheet tray 3 transport assembly removal ..........................................................................................490
2 x 500-sheet tray 4 transport assembly removal ..........................................................................................491
2 x 500-sheet tray transport assembly sensors removal ................................................................................492
2 x 500‑sheet tray tray set actuator removal .................................................................................................493
Sensor (2 x 500-sheet tray transport) removal...............................................................................................494
2 x 500-sheet tray 3 transport belts and gears removal.................................................................................495
2 x 500-sheet tray 4 transport belts and gears removal.................................................................................496
3000-sheet tray removals......................................................................................................................498
3000-sheet tray rollers removal .....................................................................................................................498
3000-sheet tray feed and pick belt removal ...................................................................................................500
3000-sheet tray caster wheel removal ........................................................................................................... 502
3000-sheet tray release handle removal ........................................................................................................503
3000-sheet tray left cover removal ................................................................................................................504
3000-sheet tray right cover removal ..............................................................................................................505
3000-sheet tray front cover removal..............................................................................................................505
3000-sheet tray rear cover removal ...............................................................................................................506
3000-sheet tray door removal ........................................................................................................................507
3000-sheet tray left top cover removal ..........................................................................................................508
Dehumidifier removal .....................................................................................................................................509
3000-sheet tray empty LED removal ..............................................................................................................510
Sensor (3000-sheet tray empty) removal .......................................................................................................510
Sensor (3000-sheet tray elevator level) removal............................................................................................511
Sensor (3000-sheet tray feed) removal ..........................................................................................................512
3000-sheet tray elevator spring removal........................................................................................................513
3000-sheet tray controller board removal .....................................................................................................513
3000-sheet tray door switch removal.............................................................................................................514
Motor (3000-sheet tray elevator) removal.....................................................................................................515
3000-sheet tray set sensor actuator removal.................................................................................................515
Sensor (3000-sheet tray set) removal.............................................................................................................516
Sensor (3000-sheet tray near empty) removal...............................................................................................517
Motor bracket removal................................................................................................................................... 519
3000-sheet tray feed and transport motors removal .....................................................................................519
3000-sheet tray feed roller assembly removal ...............................................................................................520
3000-sheet tray pick roller assembly removal................................................................................................523
Component locations...............................................................................529
Exterior locations..................................................................................................................................529
Front view .......................................................................................................................................................529
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Rear view ........................................................................................................................................................531
Maintenance............................................................................................533
Inspection guide....................................................................................................................................533
Scheduled maintenance........................................................................................................................534
Maintenance kits ............................................................................................................................................534
Resetting the maintenance counter ...............................................................................................................535
Lubrication specification.......................................................................................................................535
Cleaning the printer parts.....................................................................................................................536
Cleaning the printer ........................................................................................................................................536
Cleaning the scanner glass..............................................................................................................................536
Cleaning the charger and the printhead lens .................................................................................................537
Emptying the hole punch box .........................................................................................................................540
Parts catalog............................................................................................542
Legend...................................................................................................................................................542
Assembly 1: Covers 1.............................................................................................................................543
Assembly 2: Covers 2.............................................................................................................................545
Assembly 3: Inner covers.......................................................................................................................547
Assembly 4: Control panel 1..................................................................................................................549
Assembly 5: Control panel 2..................................................................................................................551
Assembly 6: Printhead...........................................................................................................................553
Assembly 7: Toner supply 1...................................................................................................................555
Assembly 8: Toner supply 2...................................................................................................................557
Assembly 9: Waste toner......................................................................................................................559
Assembly 10: Developer........................................................................................................................561
Assembly 11: Photoconductor lock.......................................................................................................563
Assembly 12: Transfer belt....................................................................................................................565
Assembly 13: Tray 1 and 2 transport.....................................................................................................567
Assembly 14: Tray 1 feed......................................................................................................................569
Assembly 15: Tray 1 separator..............................................................................................................571
Assembly 16: Tray 2 feed......................................................................................................................573
Assembly 17: Tray 2 separator..............................................................................................................575
Assembly 18: Tray rail...........................................................................................................................577
Assembly 19: Tray paper detection.......................................................................................................579
Assembly 20: 500-sheet tray—Tray 1...................................................................................................581
Assembly 21: 500‑sheet tray—Tray 1 or Tray 2....................................................................................583
Assembly 22: 500‑sheet tray—Tray 2...................................................................................................585
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Assembly 23: Registration transport.....................................................................................................587
Assembly 24: Transfer...........................................................................................................................589
Assembly 25: Registration unit..............................................................................................................591
Assembly 26: Right door transport........................................................................................................593
Assembly 27: MPF 1..............................................................................................................................595
Assembly 28: MPF 2..............................................................................................................................597
Assembly 29: Duplex 1..........................................................................................................................599
Assembly 30: Duplex 2..........................................................................................................................601
Assembly 31: Fuser................................................................................................................................603
Assembly 32: Exit 1................................................................................................................................605
Assembly 33: Exit 2................................................................................................................................607
Assembly 34: Main and feed drive........................................................................................................609
Assembly 35: Toner cartridge drive.......................................................................................................611
Assembly 36: Fuser drive 1....................................................................................................................613
Assembly 37: Fuser drive 2....................................................................................................................615
Assembly 38: Ozone duct......................................................................................................................617
Assembly 39: High voltage....................................................................................................................619
Assembly 40: Main power supply.........................................................................................................621
Assembly 41: Electrical 1.......................................................................................................................623
Assembly 42: Electrical 2.......................................................................................................................625
Assembly 43: ADF covers 1....................................................................................................................627
Assembly 44: ADF covers 2....................................................................................................................629
Assembly 45: ADF CIS 1.........................................................................................................................631
Assembly 46: ADF CIS 2.........................................................................................................................633
Assembly 47: ADF CIS 3.........................................................................................................................635
Assembly 48: ADF paper feed...............................................................................................................637
Assembly 49: ADF paper pick 1.............................................................................................................639
Assembly 50: ADF paper pick 2.............................................................................................................641
Assembly 51: ADF paper pick 3.............................................................................................................643
Assembly 52: ADF paper transport 1.....................................................................................................645
Assembly 53: ADF paper transport 2.....................................................................................................647
Assembly 54: ADF paper transport 3.....................................................................................................649
Assembly 55: ADF paper transport 4.....................................................................................................651
Assembly 56: ADF paper transport 5.....................................................................................................653
Assembly 57: ADF paper transport 6.....................................................................................................655
Assembly 58: Flatbed scanner covers...................................................................................................657
Assembly 59: Flatbed scanner 1............................................................................................................659
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Assembly 60: Flatbed scanner 2............................................................................................................661
Assembly 61: Flatbed scanner 3............................................................................................................663
Assembly 62: 2 x 500‑sheet tray—Covers.............................................................................................665
Assembly 63: 2 x 500‑sheet tray—Frame..............................................................................................667
Assembly 64: 2 x 500‑sheet tray—Paper feed......................................................................................669
Assembly 65: 2 x 500‑sheet tray—Paper size detection.......................................................................671
Assembly 66: 2 x 500‑sheet tray—Paper transport..............................................................................673
Assembly 67: 2 x 500‑sheet tray—Paper pick 1....................................................................................675
Assembly 68: 2 x 500‑sheet tray—Paper pick 2....................................................................................677
Assembly 69: 2 x 500‑sheet tray—Paper pick 3....................................................................................679
Assembly 70: 2 x 500‑sheet tray—Tray 3..............................................................................................681
Assembly 71: 2 x 500‑sheet tray—Tray 4..............................................................................................683
Assembly 72: 2 x 500‑sheet tray—Tray 3 or Tray 4 frame....................................................................685
Assembly 73: 3000‑sheet tray—Covers................................................................................................687
Assembly 74: 3000‑sheet tray—Frame 1..............................................................................................689
Assembly 75: 3000‑sheet tray—Frame 2..............................................................................................691
Assembly 76: 3000‑sheet tray—Elevator front section.........................................................................693
Assembly 77: 3000‑sheet tray—Paper feed 1.......................................................................................695
Assembly 78: 3000‑sheet tray—Paper feed 2.......................................................................................697
Assembly 79: 3000‑sheet tray—Paper transport..................................................................................699
Assembly 80: 3000‑sheet tray—Elevator rear section..........................................................................701
Assembly 81: 3000‑sheet tray—Drive section......................................................................................703
Assembly 82: 3000‑sheet tray—Wiring.................................................................................................705
Assembly 83: 2500-sheet tray covers....................................................................................................707
Assembly 84: 2500-sheet tray frame....................................................................................................709
Assembly 85: 2500-sheet tray paper feed.............................................................................................711
Assembly 86: 2500-sheet tray paper transport.....................................................................................713
Assembly 87: 2500-sheet tray paper pick 1..........................................................................................715
Assembly 88: 2500-sheet tray paper pick 2..........................................................................................717
Assembly 89: 2500-sheet tray paper pick 3..........................................................................................719
Assembly 90: 2500-sheet tray insert 1..................................................................................................721
Assembly 91: 2500-sheet tray insert 2..................................................................................................723
Assembly 92: 2500-sheet tray insert 3..................................................................................................725
Assembly 93: 2500-sheet tray insert 4..................................................................................................727
Assembly 94: Maintenance kits.............................................................................................................729
Assembly 95: Power cords....................................................................................................................731
Assembly 96: Miscellaneous.................................................................................................................733
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Appendix A: Printer specifications............................................................735
Power consumption..............................................................................................................................735
Product power consumption ..........................................................................................................................735
Sleep Mode .....................................................................................................................................................735
Hibernate Mode..............................................................................................................................................735
Off mode.........................................................................................................................................................736
Total energy usage..........................................................................................................................................736
Operating clearances.............................................................................................................................736
Noise emission levels............................................................................................................................737
Temperature information.....................................................................................................................737
Appendix B: Options and features............................................................739
Available internal options.....................................................................................................................739
Media handling options.........................................................................................................................739
Appendix C: Theory of operation..............................................................741
POR sequence.......................................................................................................................................741
Printer control.......................................................................................................................................741
Print cycle operation.............................................................................................................................741
Flowchart ........................................................................................................................................................741
Charge.............................................................................................................................................................742
Expose.............................................................................................................................................................742
Develop...........................................................................................................................................................742
First transfer ...................................................................................................................................................743
Clean (photoconductor)..................................................................................................................................744
Second transfer...............................................................................................................................................745
Clean (transfer belt)........................................................................................................................................745
Fuse.................................................................................................................................................................746
Printer operation...................................................................................................................................748
Printer paper path ..........................................................................................................................................748
Tray section..................................................................................................................................................... 748
MPF section ....................................................................................................................................................751
2500‑sheet tray section ..................................................................................................................................753
3000‑sheet tray section ..................................................................................................................................756
Registration section ........................................................................................................................................759
Print section....................................................................................................................................................760
Exit section......................................................................................................................................................761
Duplex section ................................................................................................................................................763
ADF operation.......................................................................................................................................765
ADF tray section configuration and paper path .............................................................................................765
ADF document feed section............................................................................................................................766
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ADF document registration section ................................................................................................................767
ADF document scanning section.....................................................................................................................767
ADF document exit section.............................................................................................................................769
Flatbed scanner operation....................................................................................................................769
Appendix D: Acronyms.............................................................................771
Acronyms...............................................................................................................................................771
Index........................................................................................................773
Part number index...................................................................................785
Part name index.......................................................................................805
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