Lexmark CX825 User manual
CX825, CX860, XC8155, and
XC8160
7564-336, -337, -536, -537, -596, -598
Service Manual
•Start diagnostics
•Maintenance
•Safety and notices
•Trademarks
•Index
January 25, 2016 www.lexmark.com
P/N 12G3414
Product information
Product name:
Lexmark CX825, CX860, XC8155, and XC8160
Machine type:
7564
Model(s):
336, 337, 536, 537, 596, 598
Edition notice
January 25, 2016
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 the Lexmark logo 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. PCL is Hewlett-Packard Company’s designation of a set of printer
commands (language) and functions included in its printer products. This printer is intended to be compatible with the PCL language.
This means the printer recognizes PCL commands used in various application programs, and that the printer emulates the functions
corresponding to the commands.
PostScript is a registered trademark of Adobe Systems Incorporated in the United States and/or other countries.
All other trademarks are the property of their respective owners.
© 2016 Lexmark International, Inc.
All rights reserved.
P/N 12G3414
7564
Table of contents
Product information......................................................................................2
Edition notice.................................................................................................2
Notices and safety information................................................................ 23
Laser notice.........................................................................................................................................................23
Avis relatif à l'utilisation du laser................................................................................................................... 23
Notificació del làser.......................................................................................................................................... 23
Aviso de láser.....................................................................................................................................................23
Aviso sobre laser...............................................................................................................................................24
Avvertenze sui prodotti laser......................................................................................................................... 24
Laserinformatie.................................................................................................................................................. 24
Lasererklæring................................................................................................................................................... 24
Laser-Hinweis.....................................................................................................................................................25
Laserilmoitus.......................................................................................................................................................25
Lasermerknad.................................................................................................................................................... 25
Meddelande om laser...................................................................................................................................... 25
レーザーについて...................................................................................................................... 26
레이저 고지사항....................................................................................................................... 26
激光注意事项............................................................................................................................26
雷射聲明................................................................................................................................... 26
Safety information............................................................................................................................................. 26
Consignes de sécurité..................................................................................................................................... 27
Informació de seguretat...................................................................................................................................27
Información de seguridad...............................................................................................................................28
Informações sobre segurança....................................................................................................................... 28
Informatie over veiligheid............................................................................................................................... 28
Informazioni sulla sicurezza............................................................................................................................29
Säkerhetsinformation.......................................................................................................................................29
Sicherheitshinweise..........................................................................................................................................30
Sikkerhedsoplysninger.................................................................................................................................... 30
Sikkerhetsinformasjon..................................................................................................................................... 30
Turvallisuusohjeet...............................................................................................................................................31
안전 정보.................................................................................................................................. 31
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安全信息................................................................................................................................... 31
安全情報................................................................................................................................... 32
安全資訊................................................................................................................................... 32
Preface......................................................................................................... 33
Conventions........................................................................................................................................................33
General caution statements............................................................................................................................33
General information................................................................................... 35
Printer model configurations..........................................................................................................................35
Finding the serial number............................................................................................................................... 36
Paper and specialty media guide..................................................................................................................37
Supported paper sizes, types, and weights..........................................................................................................37
Paper guidelines.......................................................................................................................................................... 40
Using specialty media................................................................................................................................................ 43
Data security notice..........................................................................................................................................45
Tools required for service................................................................................................................................45
Diagnostic information...............................................................................47
Troubleshooting overview...............................................................................................................................47
Performing the initial troubleshooting check........................................................................................................47
Fixing print quality issues................................................................................................................................ 47
Initial print quality check............................................................................................................................................ 48
Blank or white pages, or one color missing check............................................................................................. 49
Dark print check........................................................................................................................................................... 52
Ghost images check................................................................................................................................................... 54
Gray or colored background check........................................................................................................................ 55
Horizontal dark lines check ...................................................................................................................................... 58
Light print check .......................................................................................................................................................... 59
Mottled print and dots check ................................................................................................................................... 62
Print crooked or skewed check............................................................................................................................... 64
Solid color or black images check.......................................................................................................................... 66
Text or images cut o check .................................................................................................................................... 67
Toner easily rubs o check....................................................................................................................................... 68
Uneven print density check...................................................................................................................................... 69
Vertical dark lines or streaks check........................................................................................................................ 70
Vertical white lines or voids check ...........................................................................................................................71
Blurred print or misaligned color check ................................................................................................................ 72
Image banding check..................................................................................................................................................73
Image void (process direction) check .................................................................................................................... 75
Random marks check................................................................................................................................................. 76
Repeating defects check............................................................................................................................................77
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Fixing scan quality issues................................................................................................................................79
Dark image quality (using the ADF or scanner) check ...................................................................................... 79
Vertical lines (process direction using the ADF) check...................................................................................... 81
Spots (using the flatbed scanner) check............................................................................................................... 82
ADF skew check.......................................................................................................................................................... 83
Media damage (using the ADF) check................................................................................................................... 84
Wavy edge (ADF 2nd side scan) service check .................................................................................................. 85
Paper jams...........................................................................................................................................................87
Avoiding jams............................................................................................................................................................... 87
Identifying jam locations............................................................................................................................................ 88
Paper jam in trays........................................................................................................................................................90
Paper jam in the multipurpose feeder .................................................................................................................... 91
Paper jam in the automatic document feeder ..................................................................................................... 92
Paper jam in the standard bin.................................................................................................................................. 94
Paper jam in door B .................................................................................................................................................... 95
Paper jam in the finisher bin..................................................................................................................................... 99
Staple jam in door G...................................................................................................................................................101
Paper jam in door K ...................................................................................................................................................104
Paper jam in door J....................................................................................................................................................105
Paper jam in door N...................................................................................................................................................107
Paper jam in door L....................................................................................................................................................108
Paper jam in the staple finisher bin .......................................................................................................................109
Staple jam in door J ...................................................................................................................................................109
200 paper jams.............................................................................................................................................................111
201–202 paper jams .................................................................................................................................................136
212 paper jams............................................................................................................................................................144
213 paper jams .............................................................................................................................................................151
221–230 paper jams..................................................................................................................................................158
231 paper jams ............................................................................................................................................................166
232 paper jams........................................................................................................................................................... 173
240 paper jams...........................................................................................................................................................178
241 paper jams............................................................................................................................................................195
242 paper jams...........................................................................................................................................................196
243 paper jams ..........................................................................................................................................................207
244 paper jams ...........................................................................................................................................................218
245 paper jams..........................................................................................................................................................227
280 paper jams..........................................................................................................................................................228
281 paper jams...........................................................................................................................................................233
282 paper jams..........................................................................................................................................................239
283 paper jams..........................................................................................................................................................244
284 paper jams..........................................................................................................................................................249
288–289 paper jams................................................................................................................................................254
Procedure before starting the MSHPF service checks ...................................................................................256
Procedure before starting the mailbox service checks...................................................................................257
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40y paper jams ..........................................................................................................................................................257
41y paper jams............................................................................................................................................................266
42y paper jams ..........................................................................................................................................................273
43y paper jams...........................................................................................................................................................293
45y paper jams ..........................................................................................................................................................298
46y paper jams ..........................................................................................................................................................344
47y paper jams...........................................................................................................................................................358
48y paper jams ..........................................................................................................................................................376
User attendance messages......................................................................................................................... 388
User attendance messages (0‑99) .......................................................................................................................388
Cartridge or photoconductor error service check............................................................................................389
Mismatched paper size service check ................................................................................................................390
Insucient memory service check ........................................................................................................................391
Complex page service check..................................................................................................................................391
PPDS font error service check...............................................................................................................................392
Flash memory failure service check.....................................................................................................................392
Insucient flash memory service check .............................................................................................................393
Network service check ............................................................................................................................................394
Unsupported internal option service check.......................................................................................................396
Disabled port service check...................................................................................................................................397
Excess options service check ................................................................................................................................398
MSHPF configuration error service check..........................................................................................................398
Incompatible hardware option service check....................................................................................................402
Hard disk failure service check .............................................................................................................................403
Maintenance kit service check ..............................................................................................................................403
MSHPF staple cartridge error service check .....................................................................................................404
Printer hardware errors.................................................................................................................................406
10y errors.....................................................................................................................................................................406
110 errors......................................................................................................................................................................408
12y errors ......................................................................................................................................................................410
13y errors ......................................................................................................................................................................417
14y errors .....................................................................................................................................................................422
15y errors .....................................................................................................................................................................432
160–161 errors.............................................................................................................................................................446
162–165 errors............................................................................................................................................................449
166–169 errors............................................................................................................................................................454
17y errors......................................................................................................................................................................458
6yy errors.....................................................................................................................................................................467
Procedure before starting the 9yy service checks ..........................................................................................479
900 errors ....................................................................................................................................................................481
98y errors ....................................................................................................................................................................486
Output option hardware errors................................................................................................................... 489
302 and 323 errors...................................................................................................................................................489
36y errors ................................................................................................................................................................... 500
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374–383 errors ...........................................................................................................................................................512
Service option software error service check ......................................................................................................521
Symptoms......................................................................................................................................................... 524
Printer symptoms.......................................................................................................................................................524
Multiposition staple, hole punch finisher symptoms........................................................................................534
2-bin mailbox symptoms......................................................................................................................................... 550
Input option symptoms ............................................................................................................................................559
Staple finisher symptoms ........................................................................................................................................563
Service menus........................................................................................... 571
Understanding the printer control panel................................................................................................... 571
Using the control panel ............................................................................................................................................571
Understanding the status of the power button and indicator light..............................................................572
Using the home screen............................................................................................................................................572
Printing a menu settings page...............................................................................................................................573
Menus list.......................................................................................................................................................... 574
Diagnostics menu........................................................................................................................................... 575
Entering the Diagnostics menu .............................................................................................................................575
Event Log.....................................................................................................................................................................575
Reports.........................................................................................................................................................................576
Advanced Print Quality Samples...........................................................................................................................576
Input tray quick print.................................................................................................................................................576
Printer Setup............................................................................................................................................................... 577
Printer diagnostics and adjustments....................................................................................................................579
Additional input tray diagnostics.......................................................................................................................... 580
Output device diagnostics.......................................................................................................................................581
Scanner diagnostics .................................................................................................................................................582
Entering invalid engine mode................................................................................................................................584
Repair information................................................................................... 585
Removal precautions..................................................................................................................................... 585
Data security notice..................................................................................................................................................585
Handling ESD‑sensitive parts.................................................................................................................................586
Controller board/control panel replacement .....................................................................................................586
Restoring the printer configuration after replacing the controller board ...................................................587
Restoring solutions, licenses, and configuration settings ............................................................................. 590
Updating the printer firmware ................................................................................................................................591
Backing up eSF solutions and settings ...............................................................................................................592
Disconnecting ribbon cables..................................................................................................................................593
Adjustments..................................................................................................................................................... 593
ADF skew adjustment (front side).........................................................................................................................593
ADF skew adjustment (back side).........................................................................................................................594
ADF skew adjustment (deskew roller) .................................................................................................................595
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Printhead alignment adjustment ...........................................................................................................................596
Registration adjustment............................................................................................................................................601
Color alignment adjustment .................................................................................................................................. 602
MSHPF tamper alignment adjustment.................................................................................................................603
Removal procedures......................................................................................................................................605
Left side removals.......................................................................................................................................... 605
Left upper cover removal ....................................................................................................................................... 605
Fuser removal............................................................................................................................................................ 606
Transfer roller removal .............................................................................................................................................607
Duplex drive gears removal .................................................................................................................................. 608
Duplex release latch removal ............................................................................................................................... 608
Deskew roller sensor guide removal ....................................................................................................................610
Plastic connector cover removal............................................................................................................................612
Metal connector cover removal..............................................................................................................................612
Left door, duplex, and MPF removal......................................................................................................................613
MPF pick roller removal............................................................................................................................................616
MPF pick guide removal...........................................................................................................................................617
MPF tray stop removal ..............................................................................................................................................619
Redrive removal..........................................................................................................................................................619
Redrive gear removal................................................................................................................................................621
Sensor (input) removal ..............................................................................................................................................621
Sensor (MPF/pass-through) with deflector removal.........................................................................................622
Reference edge motor gearbox removal............................................................................................................623
Isolation roller gear removal...................................................................................................................................626
Right side removals........................................................................................................................................628
Vent cover removal...................................................................................................................................................628
Column outer cover removal..................................................................................................................................629
Right cover removal..................................................................................................................................................629
Column inner cover removal..................................................................................................................................632
Printhead fan removal..............................................................................................................................................634
Printhead removal.....................................................................................................................................................636
Motor (printhead wiper) removal...........................................................................................................................639
Front side removals........................................................................................................................................640
Keyboard attach cover removal ............................................................................................................................640
Control panel display removal................................................................................................................................641
Control panel removal..............................................................................................................................................643
Control panel button kit removal...........................................................................................................................646
Developer unit and photoconductor unit removal ...........................................................................................646
Front column upper cover removal ......................................................................................................................649
Inner upper cover removal .....................................................................................................................................649
Inner lower cover removal ..................................................................................................................................... 650
Front door removal ....................................................................................................................................................651
Transfer belt removal................................................................................................................................................652
Pick roller removal.....................................................................................................................................................654
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Separator pad removal ............................................................................................................................................655
Door rod cover removal...........................................................................................................................................656
Sensor (door interlock) removal ............................................................................................................................657
HVPS fan removal .....................................................................................................................................................658
Main HVPS removal...................................................................................................................................................661
PC unit/developer door removal...........................................................................................................................663
Lower front cover removal......................................................................................................................................664
Paper feeder removal...............................................................................................................................................665
Sensor (auto alignment) removal ..........................................................................................................................667
Sensor (TPS) removal ...............................................................................................................................................667
TPS sensor wiper removal ......................................................................................................................................668
Developer/PC unit CMY wiper rail removal........................................................................................................668
Developer/PC unit K wiper rail removal ..............................................................................................................669
Rear side removals.......................................................................................................................................... 671
Controller board cover removal .............................................................................................................................671
Rear lower cover removal .......................................................................................................................................672
Rear upper cover removal ......................................................................................................................................672
Rear left cover removal............................................................................................................................................673
Charge roller HVPS removal ..................................................................................................................................673
Controller board SIM removal................................................................................................................................675
Controller board removal ........................................................................................................................................ 677
Main fan removal .......................................................................................................................................................678
LVPS removal..............................................................................................................................................................679
LVPS cage removal....................................................................................................................................................681
Weather station removal..........................................................................................................................................683
Controller board cage removal..............................................................................................................................684
Toner add motor gearbox (K, C, and M) removal ..............................................................................................686
Toner add motor gearbox (Y) removal.................................................................................................................687
Main fan duct removal..............................................................................................................................................688
EP, developer, toner add gearbox removal ........................................................................................................689
Fuser/transfer belt motor gearbox removal .......................................................................................................692
Waste toner gear removal.......................................................................................................................................694
Toner supply actuator removal ..............................................................................................................................696
Smart chip interface board removal.....................................................................................................................697
Toner cartridge contact removal ...........................................................................................................................698
Toner add tube removal ..........................................................................................................................................700
Top side removals...........................................................................................................................................703
Top cover removal.....................................................................................................................................................703
Standard bin cover removal ...................................................................................................................................705
Sensor cover removal ..............................................................................................................................................707
ADF and flatbed removals............................................................................................................................709
ADF pick roller cover removal ...............................................................................................................................709
ADF pick roller removal ............................................................................................................................................710
ADF feed belt removal..............................................................................................................................................710
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ADF rear cover removal.............................................................................................................................................711
ADF removal.................................................................................................................................................................711
ADF controller board removal.................................................................................................................................712
ADF tray removal........................................................................................................................................................ 713
ADF front cover removal .......................................................................................................................................... 713
ADF bottom door removal .......................................................................................................................................714
Top interlock actuator removal ...............................................................................................................................716
ADF front drive train removal.................................................................................................................................. 717
Motor (ADF) removal..................................................................................................................................................718
Motor (ADF calibration roller) removal..................................................................................................................721
ADF top door with hinge removal.........................................................................................................................722
ADF top door cover removal..................................................................................................................................724
ADF rear drive gears removal................................................................................................................................724
Bottom interlock actuator removal .......................................................................................................................725
ADF separator roller removal.................................................................................................................................726
Input guide removal.................................................................................................................................................. 727
Sensor (ADF multifeed receiver) removal........................................................................................................... 727
Sensor (ADF multifeed transmitter) removal ......................................................................................................728
CCDM (ADF) removal ...............................................................................................................................................728
ADF media exit actuator removal..........................................................................................................................730
Sensor (ADF 2nd scan) removal............................................................................................................................. 731
Flatbed scanner front upper cover removal.......................................................................................................732
Flatbed scanner left cover removal...................................................................................................................... 733
Flatbed scanner right cover removal ................................................................................................................... 733
Flatbed scanner rear cover removal ....................................................................................................................735
Flatbed scanner top cover removal......................................................................................................................736
Flatbed scanner support removal......................................................................................................................... 737
Flatbed scanner frame latch removal ..................................................................................................................739
Flatbed scanner CCDM removal ...........................................................................................................................740
Flatbed scanner board removal ............................................................................................................................742
Flatbed scanner gear removal............................................................................................................................... 744
Motor (flatbed scanner) removal ...........................................................................................................................745
Sensor (flatbed scanner home position) ............................................................................................................. 747
Flatbed scanner tensioner pulley removal .........................................................................................................749
550-sheet tray removals...............................................................................................................................752
550-sheet tray media size sensor actuators removal .....................................................................................752
Sensor (550-sheet tray media size) removal .....................................................................................................752
Sensor (550-sheet tray media low) removal ......................................................................................................753
Sensor (550-sheet tray jam door) .........................................................................................................................754
550-sheet tray right rail removal...........................................................................................................................754
550-sheet tray paper feeder removal .................................................................................................................755
Sensor (550-sheet tray media out) removal.......................................................................................................755
550-sheet tray rear cover removal.......................................................................................................................756
550-sheet tray controller board removal............................................................................................................ 757
550-sheet tray interface cable removal.............................................................................................................. 757
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Sensor (550-sheet tray pick roller index) removal ...........................................................................................760
550-sheet tray left rail removal...............................................................................................................................761
Motor (550-sheet tray pass‑through) removal...................................................................................................762
550-sheet tray wake up switch removal.............................................................................................................763
2200-sheet tray removals............................................................................................................................ 765
2200-sheet tray insert removal.............................................................................................................................765
Bell crank removal.....................................................................................................................................................765
2200-sheet tray rail removal..................................................................................................................................766
Sensor (2200-sheet tray media low) removal ................................................................................................... 767
Sensor (2200-sheet tray media size) removal................................................................................................... 767
2200-sheet tray rear cover removal ....................................................................................................................768
2200-sheet tray controller board removal .........................................................................................................768
2200-sheet tray interface cable removal ...........................................................................................................769
2200-sheet tray elevator gears removal ............................................................................................................. 771
Motor (2200-sheet tray elevator) removal.......................................................................................................... 772
2200-sheet tray paper feeder removal............................................................................................................... 774
Sensor (2200-sheet tray media out) removal.................................................................................................... 774
Sensor (2200-sheet tray pick roller index) removal......................................................................................... 775
Motor (2200-sheet tray pick) removal ................................................................................................................. 776
2200-sheet tray media out sensor actuator removal.......................................................................................777
2200-sheet tray wake up switch removal ..........................................................................................................780
Caster base removals..................................................................................................................................... 781
Locking caster removal.............................................................................................................................................781
Non‑locking caster removal ...................................................................................................................................784
Staple finisher removals................................................................................................................................ 787
Staple finisher right cover removal....................................................................................................................... 787
Staple finisher front cover removal....................................................................................................................... 787
Staple finisher rear cover removal........................................................................................................................788
Staple finisher controller board removal.............................................................................................................790
Staple finisher staple cartridge door removal....................................................................................................790
Staple finisher jam access door removal .............................................................................................................791
Staple finisher lock assembly removal .................................................................................................................791
Staple finisher bottom cover removal..................................................................................................................794
Staple finisher staple cartridge door switch removal ......................................................................................794
Staple finisher inner rear cover removal.............................................................................................................795
Sensor (staple finisher lower bin full) removal...................................................................................................796
Sensor (staple finisher upper bin full) removal ..................................................................................................798
Motor (staple finisher upper exit roller) removal ...............................................................................................799
Staple finisher rear upper position exit roller gears removal ....................................................................... 800
Staple finisher staple unit ejector removal .........................................................................................................803
Sensor (staple finisher stack clamp) removal.....................................................................................................804
Staple finisher staple unit removal....................................................................................................................... 805
Staple finisher jam door switches removal.........................................................................................................807
Staple finisher stack clamp removal.....................................................................................................................808
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Staple finisher stack clamp solenoid removal ....................................................................................................810
Motor (staple finisher aligner paddle) removal ..................................................................................................812
Staple finisher transport gears removal ...............................................................................................................812
Staple finisher aligner paddle gears removal.....................................................................................................814
Sensor (staple finisher upper exit roller) removal..............................................................................................816
Staple finisher exit gears removal..........................................................................................................................817
Staple finisher front upper position exit roller gears removal ........................................................................819
Staple finisher exit roller belts removal ................................................................................................................821
Staple finisher tamper assembly removal...........................................................................................................822
Staple finisher tamper top cover removal...........................................................................................................824
Sensor (staple finisher tamper position) removal .............................................................................................825
Motor (staple finisher tamper) removal................................................................................................................825
Staple finisher tamper belts removal ...................................................................................................................827
Staple finisher tamper pulley gear removal .......................................................................................................828
Staple finisher tamper removal..............................................................................................................................829
Staple finisher bin link removal...............................................................................................................................831
Staple finisher bin removal .....................................................................................................................................832
Staple finisher compiler feed roller removal......................................................................................................834
Staple finisher compiler paper guide removal...................................................................................................836
Staple finisher compiler feed idler removal........................................................................................................837
Staple finisher aligner paddle and upper paper guide removal...................................................................838
Staple finisher upper exit roller removal ..............................................................................................................841
Staple finisher entrance paper guide removal ..................................................................................................844
Staple finisher bin clamp assembly removal......................................................................................................846
Sensor (staple finisher bin clamp) removal.........................................................................................................853
Motor (staple finisher bin clamp) removal...........................................................................................................854
Motor (staple finisher exit) removal ......................................................................................................................859
Motor (staple finisher transport) removal............................................................................................................859
Staple finisher decurl assembly removal .............................................................................................................861
Sensor (staple finisher staple unit paper present) removal ...........................................................................862
Sensor (staple finisher decurl) removal...............................................................................................................863
Sensor (staple finisher transport) removal..........................................................................................................864
Horizontal paper transport removals.........................................................................................................866
HPT front cover removal .........................................................................................................................................866
HPT front inner cover removal...............................................................................................................................867
Sensor (HPT jam cover) removal...........................................................................................................................867
HPT front transport belt removal...........................................................................................................................868
HPT front transport belt gear removal.................................................................................................................868
HPT rear cover removal...........................................................................................................................................869
HPT fan removal ........................................................................................................................................................870
HPT controller board removal................................................................................................................................870
HPT transport belts removal....................................................................................................................................871
Hole punch unit cover removal .............................................................................................................................873
Hole punch unit removal .........................................................................................................................................874
Motor (hole punch unit) removal ...........................................................................................................................874
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Hole punch unit gears removal .............................................................................................................................875
Sensor (hole punch unit) removal .........................................................................................................................876
HPT transport assembly removal..........................................................................................................................878
Motor (HPT transport) removal ..............................................................................................................................879
HPT transport gears removal ..................................................................................................................................881
HPT transport drive belt removal..........................................................................................................................883
HPT top cover removal............................................................................................................................................884
HPT transport idler roller removal ........................................................................................................................885
HPT top door removal..............................................................................................................................................888
HPT lock removal ......................................................................................................................................................888
HPT autoconnect cable removal............................................................................................................................891
Sensor (HPT transport) removal ............................................................................................................................895
Sensor (HPU entrance) removal............................................................................................................................897
HPT alignment rollers removal ..............................................................................................................................899
HPT transport rollers removal................................................................................................................................903
Multiposition staple, hole punch finisher removals..................................................................................911
MSHPF power supply cover removal.....................................................................................................................911
MSHPF bottom left cover removal..........................................................................................................................911
MSHPF front door removal ......................................................................................................................................912
Knobs J2 and J7 removal.........................................................................................................................................914
MSHPF door hinge removal ....................................................................................................................................915
MSHPF front left cover removal .............................................................................................................................916
MSHPF inner front cover removal..........................................................................................................................917
MSHPF staple cartridge door removal .................................................................................................................919
MSHPF left front cover removal .............................................................................................................................921
MSHPF right cover removal....................................................................................................................................922
MSHPF bottom right cover removal.....................................................................................................................923
Stapler bin cave cover removal.............................................................................................................................924
MSHPF bin light board removal.............................................................................................................................926
MSHPF right frame cover removal........................................................................................................................927
MSHPF controller board cover removal..............................................................................................................930
MSHPF rear cover removal......................................................................................................................................931
MSHPF power supply removal ..............................................................................................................................933
MSHPF inner top cover removal ...........................................................................................................................934
MSHPF top frame covers removal........................................................................................................................935
MSHPF controller board removal..........................................................................................................................937
Switch (MSHPF cartridge door interlock) removal............................................................................................940
Sensor (cartridge loading position) removal ......................................................................................................942
Sensor (stapler bin lower limit) removal ..............................................................................................................942
MSHPF staple unit carriage removal....................................................................................................................944
Sensor (MSHPF staple unit position) removal....................................................................................................947
Sensor (MSHPF staple unit paper present) removal.........................................................................................951
MSHPF staple unit removal ....................................................................................................................................955
Staple unit extension cable removal....................................................................................................................958
Sensor (MSHPF door interlock) removal..............................................................................................................961
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Sensor (stapler bin stack upper limit) removal ..................................................................................................962
Compiler entrance belt tensioner removal.........................................................................................................964
Hole punch box belt removal.................................................................................................................................966
Hole punch box pulley gear removal...................................................................................................................967
Staging outer transport belt removal ...................................................................................................................969
Staging outer transport pulley gear removal ......................................................................................................971
Motor (staging diverter) removal...........................................................................................................................973
Sensor (staging diverter) removal.........................................................................................................................975
Sensor (hole punch box present) removal..........................................................................................................978
Motor (staging outer transport) removal .............................................................................................................978
Motor (staging inner transport) removal..............................................................................................................982
Staging transport gears removal...........................................................................................................................986
Staging transport belts removal ........................................................................................................................... 990
Oset belt tensioner removal ................................................................................................................................994
MSHPF standard bin exit belt removal................................................................................................................996
Mid-transport pulley gears removal......................................................................................................................998
Motor (mid-transport) removal ..............................................................................................................................1001
Mid-transport gear removal ..................................................................................................................................1003
Mid-transport interface board removal..............................................................................................................1005
Mid-transport (HPT) interface cable removal ...................................................................................................1006
Mid-transport (mailbox) interface cable removal.............................................................................................1008
Sensor (standard bin stack upper limit) removal............................................................................................... 1011
Standard bin elevator drive removal...................................................................................................................1012
Motor (standard bin elevator) removal................................................................................................................ 1013
Sensor (standard bin paper present) removal .................................................................................................. 1014
Sensor (oset roller) removal ................................................................................................................................1019
MSHPF top frame removal.....................................................................................................................................1019
Oset assembly removal....................................................................................................................................... 1024
Motor (mid-transport diverter) removal.............................................................................................................. 1032
Sensor (mid-transport diverter 1) removal......................................................................................................... 1033
Mid-transport diverter cams and gear removal............................................................................................... 1035
Sensor (hole punch box full, receiver) removal............................................................................................... 1038
Sensor (hole punch box full, transmitter) removal .......................................................................................... 1043
Mid-transport mailbox entrance frame removal .............................................................................................. 1048
Mid-transport diverter 1 removal..........................................................................................................................1052
Mid-transport guide removal................................................................................................................................1055
Door J1 removal .......................................................................................................................................................1056
Mid-transport diverter 2 removal ........................................................................................................................1058
Sensor (MSHPF standard bin exit) removal.......................................................................................................1061
Sensor (door N interlock) removal ...................................................................................................................... 1064
Sensor (mid-transport) removal ...........................................................................................................................1068
Sensor (staging outer transport 1) removal....................................................................................................... 1073
Sensor (staging entrance) removal..................................................................................................................... 1078
Mid-transport and staging assembly removals ...............................................................................................1085
Mid-transport and staging assembly removal.............................................................................................1085
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MSHPF standard bin assembly removal .......................................................................................................1091
Staging paper guide removal.......................................................................................................................... 1094
Staging inner transport roller removal ..........................................................................................................1096
Staging diverter removal ..................................................................................................................................1099
Staging exit guide removal ...............................................................................................................................1106
Multiposition stapler assembly removals............................................................................................................ 1114
Multiposition stapler assembly removal......................................................................................................... 1114
Motor (MSHPF front tamper) removal ............................................................................................................ 1123
Motor (MSHPF rear tamper) removal.............................................................................................................. 1124
MSHPF tamper belt removal ............................................................................................................................ 1125
MSHPF tamper pulley gear removal .............................................................................................................. 1126
Sensor (MSHPF tamper) removal .................................................................................................................... 1127
MSHPF tampers removal................................................................................................................................... 1128
Compiler interface board removal.................................................................................................................. 1132
Motor (compiler stack height) removal .......................................................................................................... 1132
Sensor (compiler stack height) removal ........................................................................................................ 1134
Stack height assembly removal....................................................................................................................... 1135
Sensor (compiler exit cam) removal ............................................................................................................... 1136
Sensor (compiler paddle) removal...................................................................................................................1137
Motor (compiler exit cam) removal ................................................................................................................. 1139
Compiler paddle and exit drive removal....................................................................................................... 1140
Compiler exit roller removal ............................................................................................................................. 1142
Motor (compiler paddle) removal.................................................................................................................... 1143
Stapler bin lower exit roller belt removal ...................................................................................................... 1144
Stapler bin lower exit roller pulley gear removal ........................................................................................ 1145
Compiler entrance guide removal .................................................................................................................. 1145
Compiler entrance upper roller removal........................................................................................................1147
Compiler gears removal .................................................................................................................................... 1149
MSHPF compiler tray removal ......................................................................................................................... 1153
Sensor (compiler paper present) removal .................................................................................................... 1156
Motor (MSHPF bin clamp) removal ................................................................................................................. 1157
Sensor (MSHPF bin clamp home) removal ................................................................................................... 1157
Stapler bin lower exit roller removal............................................................................................................... 1158
Motor (stapler bin elevator) removal ..............................................................................................................1160
Stapler bin elevator drive removal.................................................................................................................. 1163
Staple unit carriage belt removal .................................................................................................................... 1167
Motor (staple unit carriage) removal............................................................................................................... 1167
Staple unit cable removal.................................................................................................................................. 1169
Stapler bin assembly removal.......................................................................................................................... 1176
Stapler bin assembly cables removal ............................................................................................................. 1181
Sensor (staging inner transport 1) removal ................................................................................................... 1182
Sensor (staging inner transport 2) removal .................................................................................................. 1183
Cabinet removals ..................................................................................................................................................... 1184
Cabinet door removal......................................................................................................................................... 1184
Cabinet door hinge removal............................................................................................................................. 1185
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Cabinet removal................................................................................................................................................... 1185
Cabinet right wheel removal .............................................................................................................................1187
Cabinet left wheel removal............................................................................................................................... 1188
Cabinet brackets removal ................................................................................................................................. 1189
Cabinet upper covers removal ........................................................................................................................1190
Cabinet lower covers removal ......................................................................................................................... 1193
Finisher lock button removal............................................................................................................................ 1197
Finisher lock latch removal ..............................................................................................................................1200
2-bin mailbox removals................................................................................................................................1203
Mailbox bail removal............................................................................................................................................... 1203
Mailbox jam door removal..................................................................................................................................... 1204
Mailbox front cover removal................................................................................................................................. 1204
Motor (mailbox diverter) removal ........................................................................................................................1205
Mailbox rear cover removal ..................................................................................................................................1206
Mailbox controller board removal ....................................................................................................................... 1207
Motor (mailbox transport) removal......................................................................................................................1208
Sensor (mailbox jam door) removal....................................................................................................................1209
Mailbox interface cable removal ..........................................................................................................................1210
Mailbox latch removal .............................................................................................................................................. 1211
Mailbox bottom cover removal ............................................................................................................................. 1213
Mailbox top cover removal .................................................................................................................................... 1213
Mailbox front inner cover removal....................................................................................................................... 1214
Sensor (mailbox diverter home) removal ........................................................................................................... 1215
Mailbox diverter removal........................................................................................................................................ 1216
Mailbox diverter gear removal.............................................................................................................................. 1217
Mailbox rear inner cover removal ........................................................................................................................ 1218
Sensor (mailbox bin 1 full) removal....................................................................................................................... 1219
Sensor (mailbox bin 2 full) removal.....................................................................................................................1220
Mailbox drive belt removal..................................................................................................................................... 1221
Mailbox bin 2 full sensor flag removal ................................................................................................................ 1221
Mailbox bin 1 full sensor flag removal ................................................................................................................ 1223
Sensor (mailbox bin 2 paper present) removal ............................................................................................... 1224
Sensor (mailbox bin 1 paper present) removal.................................................................................................1226
Bin light board removal.......................................................................................................................................... 1227
Sensor (mailbox transport) removal.................................................................................................................... 1228
Mailbox bin 2 pulley gear removal...................................................................................................................... 1230
Mailbox bin 1 pulley gear removal....................................................................................................................... 1232
Mailbox drive gears removal ................................................................................................................................ 1233
Component locations............................................................................. 1237
Printer configurations................................................................................................................................... 1237
Printer roller locations.................................................................................................................................. 1239
Printer sensor locations................................................................................................................................ 1241
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Printer motor locations.................................................................................................................................1243
Power supply locations—Rear....................................................................................................................1245
ADF roller locations...................................................................................................................................... 1246
ADF sensor locations....................................................................................................................................1247
Staple finisher locations...............................................................................................................................1248
HPT locations................................................................................................................................................. 1250
MSHPF sensor locations............................................................................................................................. 1252
MSHPF motor locations...............................................................................................................................1255
Mailbox locations...........................................................................................................................................1258
Maintenance............................................................................................ 1261
Scheduled maintenance...............................................................................................................................1261
Maintenance kits....................................................................................................................................................... 1261
Resetting the maintenance counter .................................................................................................................... 1261
Cleaning printer parts.................................................................................................................................. 1262
Cleaning the printer................................................................................................................................................1262
Cleaning the scanner glass .................................................................................................................................. 1263
Emptying the hole punch box .............................................................................................................................. 1264
Parts catalog............................................................................................1266
Legend............................................................................................................................................................. 1266
Assembly 1: Covers 1.....................................................................................................................................1267
Assembly 2: Covers 2.................................................................................................................................. 1269
Assembly 3: Covers 3....................................................................................................................................1271
Assembly 4: Control panel.......................................................................................................................... 1273
Assembly 5: Duplex...................................................................................................................................... 1275
Assembly 6: Left door...................................................................................................................................1277
Assembly 7: Feeder...................................................................................................................................... 1279
Assembly 8: Frame........................................................................................................................................ 1281
Assembly 9: Fuser.........................................................................................................................................1283
Assembly 10: Electronics—Front............................................................................................................... 1285
Assembly 11: Electronics—Rear.................................................................................................................. 1287
Assembly 12: Registration........................................................................................................................... 1289
Assembly 13: Motors......................................................................................................................................1291
Assembly 14: Printhead................................................................................................................................1293
Assembly 15: Toner supply......................................................................................................................... 1295
Assembly 16: Redrive....................................................................................................................................1297
Assembly 17: Transfer—Front..................................................................................................................... 1299
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Assembly 18: Transfer—Rear....................................................................................................................... 1301
Assembly 19: ADF 1....................................................................................................................................... 1303
Assembly 20: ADF 2.....................................................................................................................................1305
Assembly 21: ADF 3...................................................................................................................................... 1307
Assembly 22: ADF 4.....................................................................................................................................1309
Assembly 23: ADF 5....................................................................................................................................... 1311
Assembly 24: ADF 6...................................................................................................................................... 1313
Assembly 25: Flatbed scanner 1.................................................................................................................1315
Assembly 26: Flatbed scanner 2................................................................................................................1317
Assembly 27: Flatbed scanner 3................................................................................................................ 1319
Assembly 28: 550-sheet tray......................................................................................................................1321
Assembly 29: 550‑sheet tray—Rear.........................................................................................................1323
Assembly 30: 550‑sheet tray—Front....................................................................................................... 1325
Assembly 31: 2200‑sheet tray....................................................................................................................1327
Assembly 32: 2200‑sheet tray—Front.....................................................................................................1329
Assembly 33: 2200‑sheet tray—Rear....................................................................................................... 1331
Assembly 34: Caster base...........................................................................................................................1333
Assembly 35: Cables....................................................................................................................................1335
Assembly 36: Maintenance kits................................................................................................................. 1337
Assembly 37: Power cords..........................................................................................................................1339
Assembly 38: Miscellaneous....................................................................................................................... 1341
Assembly 39: Staple finisher option.........................................................................................................1343
Assembly 40: Staple finisher—Covers.....................................................................................................1345
Assembly 41: Staple finisher—Front..........................................................................................................1347
Assembly 42: Staple finisher—Electrical................................................................................................. 1349
Assembly 43: Staple finisher—Rear...........................................................................................................1351
Assembly 44: Staple finisher—Tamper....................................................................................................1353
Assembly 45: Staple finisher—Transport................................................................................................ 1355
Assembly 46: Staple finisher—Bottom.....................................................................................................1357
Assembly 47: Mailbox 1................................................................................................................................1359
Assembly 48: Mailbox 2................................................................................................................................1361
Assembly 49: Mailbox 3...............................................................................................................................1363
Assembly 50: Mailbox 4.............................................................................................................................. 1365
Assembly 51: Mailbox 5................................................................................................................................1367
Assembly 52: HPT 1...................................................................................................................................... 1369
Assembly 53: HPT 2.......................................................................................................................................1371
Assembly 54: HPT 3......................................................................................................................................1373
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Assembly 55: HPT 4..................................................................................................................................... 1375
Assembly 56: HPT 5......................................................................................................................................1377
Assembly 57: MSHPF covers 1...................................................................................................................1379
Assembly 58: MSHPF covers 2.................................................................................................................. 1381
Assembly 59: MSHPF electronics.............................................................................................................1383
Assembly 60: MSHPF mid-transport drive..............................................................................................1385
Assembly 61: MSHPF mid-transport paper path....................................................................................1387
Assembly 62: MSHPF oset drive............................................................................................................ 1389
Assembly 63: MSHPF standard bin 1.........................................................................................................1391
Assembly 64: MSHPF standard bin 2.......................................................................................................1393
Assembly 65: MSHPF transport roller and hole punch box...............................................................1395
Assembly 66: MSHPF staging drive......................................................................................................... 1397
Assembly 67: MSHPF staging paper path.............................................................................................. 1399
Assembly 68: MSHPF compiler 1................................................................................................................1401
Assembly 69: MSHPF compiler 2............................................................................................................. 1403
Assembly 70: MSHPF tamper.................................................................................................................... 1405
Assembly 71: MSHPF carriage transport ................................................................................................ 1407
Assembly 72: MSHPF door interlock....................................................................................................... 1409
Assembly 73: MSHPF stapler bin 1..............................................................................................................1411
Assembly 74: MSHPF stapler bin 2............................................................................................................1413
Assembly 75: MSHPF stapler bin 3............................................................................................................1415
Assembly 76: MSHPF cabinet..................................................................................................................... 1417
Assembly 77: Miscellaneous, MSHPF....................................................................................................... 1419
Appendix A: Printer specifications........................................................1421
Power consumption.......................................................................................................................................1421
Product power consumption................................................................................................................................. 1421
Sleep Mode................................................................................................................................................................ 1421
Hibernate Mode........................................................................................................................................................ 1421
O mode.................................................................................................................................................................... 1422
Total energy usage ................................................................................................................................................. 1422
Selecting a location for the printer........................................................................................................... 1422
Noise emission levels...................................................................................................................................1423
Temperature information............................................................................................................................. 1423
Appendix B: Options and features....................................................... 1425
Available internal options............................................................................................................................1425
Input/output configurations and capacities............................................................................................1425
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Input capacity by paper and source.........................................................................................................1426
Output capacity by paper and source......................................................................................................1427
Physical specifications (input options)..................................................................................................... 1428
Output options supported...........................................................................................................................1428
Appendix C: Theory of operation......................................................... 1429
POR sequence............................................................................................................................................... 1429
Print cycle operation.....................................................................................................................................1429
Print engine layout .................................................................................................................................................. 1429
Print cycle .................................................................................................................................................................. 1430
Fresh toner delivery drive ..................................................................................................................................... 1439
Developer drive ....................................................................................................................................................... 1440
Photoconductor drive.............................................................................................................................................. 1441
Black only retract (BOR) drive .............................................................................................................................. 1442
Waste toner delivery drive.................................................................................................................................... 1443
Printhead lens cleaner drive................................................................................................................................. 1444
Printer operation............................................................................................................................................1445
Printer sections ........................................................................................................................................................ 1445
Printer paper path ................................................................................................................................................... 1446
Printer paper path sensors ................................................................................................................................... 1448
MPF pick drive.......................................................................................................................................................... 1450
Tray 1 lift and pick drive........................................................................................................................................... 1451
MPF/pass-through and isolation drive............................................................................................................... 1452
Registration drive..................................................................................................................................................... 1453
Transfer belt drive ................................................................................................................................................... 1454
Fuser drive ................................................................................................................................................................ 1455
Exit and redrive drive ............................................................................................................................................. 1456
Diverter drive.............................................................................................................................................................1457
Duplex path drive .................................................................................................................................................... 1459
ADF and scanner operation....................................................................................................................... 1460
Flatbed scanner drive ............................................................................................................................................ 1460
ADF paper path......................................................................................................................................................... 1461
ADF paper path sensors........................................................................................................................................ 1462
ADF double‑feed detection.................................................................................................................................. 1463
ADF tray lift drive..................................................................................................................................................... 1465
ADF tray pick and feed drive................................................................................................................................ 1466
ADF separator drive.................................................................................................................................................1467
ADF registration drive ............................................................................................................................................ 1468
ADF scan and exit drive......................................................................................................................................... 1469
ADF calibration drive.............................................................................................................................................. 1470
2200-sheet tray operation........................................................................................................................... 1471
Paper presence and size detection......................................................................................................................1471
Paper lift and feed....................................................................................................................................................1472
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20
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