Lexmark M5150 User manual

MS71x, MS81x, & M51xx
Machine Type 4063-2xx, -4xx, -63x, -83x
Service Manual
•Start diagnostics
•Maintenance
•Safety and notices
•Trademarks
•Index
August 23, 2013 www.lexmark.com
P/N 12G3023

Product information
Product name:
Lexmark MS71x and MS81x Series
Machine type:
4063
Model(s):
2xx, 4xx, 63x, 83x
Edition notice
August 23, 2013
The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL,
INC., PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED
TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of
express or implied warranties in certain transactions; therefore, this statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these
changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any
time.
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all
countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product,
program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual
property right may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services,
except those expressly designated by the manufacturer, are the user’s responsibility.
Trademarks
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other
countries.
PrintCryption is a trademark of Lexmark International, Inc.
Mac and the Mac logo are trademarks of Apple Inc., registered in the U.S. and 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.
All other trademarks are the property of their respective owners.
© 2012 Lexmark International, Inc.
All rights reserved.
P/N 12G3023
4063

Table of contents
Product information.....................................................................................2
Edition notice...............................................................................................2
Notices and safety information..................................................................23
Laser notices............................................................................................................................................23
Safety information...................................................................................................................................26
Preface.......................................................................................................31
Service manual conventions....................................................................................................................31
Change history.........................................................................................................................................31
General information...................................................................................41
Media guidelines.....................................................................................................................................42
Paper guidelines ...............................................................................................................................................42
Paper characteristics ....................................................................................................................................42
Unacceptable paper .....................................................................................................................................43
Selecting paper.............................................................................................................................................43
Selecting preprinted forms and letterhead..................................................................................................43
Storing paper................................................................................................................................................ 44
Using recycled paper and other office papers .................................................................................................. 44
Using specialty media .......................................................................................................................................45
Tips on using card stock ...............................................................................................................................45
Tips on using envelopes ...............................................................................................................................46
Tips on using labels ...................................................................................................................................... 46
Tips on using letterhead...............................................................................................................................46
Tips on using transparencies ........................................................................................................................ 47
Supported paper sizes, types, and weights ......................................................................................................47
Paper types and weights supported by the printer......................................................................................47
Paper sizes supported by the printer ...........................................................................................................48
Paper sizes, types, and weights supported by the optional finishers .......................................................... 49
Data security notice.................................................................................................................................51
Tools required for service........................................................................................................................51
Diagnostic information...............................................................................53
Troubleshooting overview.......................................................................................................................53
Performing the initial troubleshooting check ...................................................................................................53
Power‑on Reset (POR) sequence ...................................................................................................................... 54
Using Safe Mode...............................................................................................................................................54
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Fixing print quality issues........................................................................................................................55
Initial print quality check ..................................................................................................................................55
Gray background on prints ...............................................................................................................................56
Printer is printing blank pages ..........................................................................................................................57
Printer is printing solid black pages ..................................................................................................................58
Repeating defects ............................................................................................................................................. 58
Shadow images appear on prints .....................................................................................................................59
Skewed print.....................................................................................................................................................59
Streaked horizontal lines appear on prints.......................................................................................................61
Streaked vertical lines appear on prints ...........................................................................................................62
Toner rubs off ................................................................................................................................................... 63
Paper jams...............................................................................................................................................63
Understanding jam messages and locations.....................................................................................................64
200 paper jams .................................................................................................................................................66
[x]‑page jam, lift front cover to remove cartridge. [200–201] ..................................................................... 66
200 paper jam messages..............................................................................................................................69
Sensor (input) static jam service check ........................................................................................................70
Sensor (input) early arriving jam service check............................................................................................71
Sensor (input) never‑or late‑arriving jam service check ............................................................................. 72
Sensor (input) late-leaving or did-not-clear jam service check ....................................................................74
Main drive motor control jam service check................................................................................................75
Printhead motor control jam service check .................................................................................................76
Fuser drive motor control jam service check ...............................................................................................76
Sensor (input) miscellaneous jam 1 service check .......................................................................................76
Sensor (input) miscellaneous jam 2 service check .......................................................................................77
Sensor (input) miscellaneous jam 3 service check .......................................................................................77
202 paper jams .................................................................................................................................................78
[x]‑page jam, open upper rear door. [202] ..................................................................................................78
202 paper jam messages..............................................................................................................................79
Sensor (fuser exit) static jam service check..................................................................................................80
Sensor (fuser exit) late-leaving jam service check........................................................................................81
Sensor (fuser exit) late-arriving jam service check.......................................................................................82
Sensor (narrow media) late arriving jam service check................................................................................83
Sensor (narrow media) static jam service check ..........................................................................................84
Sensor (fuser exit) miscellaneous jam service check....................................................................................84
Fuser ID chip control jam service check ....................................................................................................... 85
203 paper jams .................................................................................................................................................85
[x]‑page jam, remove standard bin jam. [203].............................................................................................85
203 paper jam messages..............................................................................................................................86
Upper redrive motor control jam service check...........................................................................................86
23y paper jams ................................................................................................................................................. 87
[x]‑page jam, open upper and lower rear door. [231–234] ......................................................................... 87
[x]‑page jam, remove tray 1 to clear duplex. [235–239]..............................................................................89
23y paper jam messages ..............................................................................................................................90
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Sensor (duplex path) static jam service check.............................................................................................. 90
Sensor (duplex path) early arriving jam service check .................................................................................91
Sensor (duplex path) never‑or late‑arriving jam service check................................................................... 92
Sensor (duplex path) late leaving jam service check....................................................................................93
Duplex control jam service check.................................................................................................................94
Sensor (duplex path) miscellaneous jam service check ...............................................................................94
Sensor (input) never-arriving jam (exiting duplex) service check ................................................................95
24y paper jams ................................................................................................................................................. 96
[x]‑page jam, open tray [x]. [24y].................................................................................................................96
24y paper jam messages ..............................................................................................................................97
Media feeder motor control service check ................................................................................................109
Media tray 1, tray pulled jam .....................................................................................................................110
Media feeder motor tray lift error service check .......................................................................................111
Sensor (input) never-arriving jam from tray 1 service check .....................................................................111
250/550-sheet media tray option jam service check .................................................................................113
HCIT jam service check ............................................................................................................................... 115
HCIT source jam service check ...................................................................................................................118
250 paper jams ...............................................................................................................................................120
[x]‑page jam, clear manual feeder. [250] ...................................................................................................120
250 paper jam messages............................................................................................................................121
Sensor (input) never-arriving jam from MPF media tray service check ..................................................... 122
4yy paper jams................................................................................................................................................123
[x]‑page jam, remove paper, open expander rear door. Leave paper in bin. [41y.xx]...............................123
[x]‑page jam, remove paper, open mailbox rear door. Leave paper in bin. [43y.xx] .................................124
[x]‑page jam, remove paper, open finisher rear door. Leave paper in bin. [451] ......................................126
[x]‑page jam, remove paper, open stapler door. Leave paper in bin. [455–457]....................................... 127
4yy paper jam messages ............................................................................................................................130
Sensor (mailbox pass through) jam service check...................................................................................... 139
Mailbox main motor jam service check......................................................................................................142
Mailbox diverter plunger jam service check ..............................................................................................144
Mailbox diverter jam service check............................................................................................................145
HCOE diverter jam service check................................................................................................................148
Sensor (HCOE pass through) jam service check .........................................................................................150
HCOE media entrance jam service check ...................................................................................................153
HCOE main motor jam service check .........................................................................................................156
Sensor (finisher pass through) jam service check ......................................................................................158
Finisher left tamper jam service check.......................................................................................................161
Finisher right tamper jam service check.....................................................................................................163
Finisher ejector jam service check .............................................................................................................165
Finisher main motor jam service check......................................................................................................166
Finisher diverter jam service check ............................................................................................................ 168
Finisher tray holder jam service check .......................................................................................................170
Finisher paddle jam service check..............................................................................................................171
Stapler carriage jam service check .............................................................................................................173
Sensor (throat media present) jam service check ...................................................................................... 175
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Finisher (HPU) main motor jam service check ........................................................................................... 178
Finisher (HPU) ejector jam service check ................................................................................................... 179
Sensor (HPU finisher pass through) jam service check ..............................................................................180
Finisher (HPU) left tamper jam service check ............................................................................................183
Finisher (HPU) right tamper jam service check ..........................................................................................184
Finisher (HPU) diverter jam service check..................................................................................................186
Finisher (HPU) paddle jam service check ...................................................................................................187
Finisher (HPU) tray holder jam service check............................................................................................. 189
Sensor (HPU throat media present) jam service check ..............................................................................190
Stapler carriage (HPU) jam service check...................................................................................................193
HPU feed motor jam service check ............................................................................................................195
Sensor (HPU media align) jam service check..............................................................................................196
Sensor (HPU trailing edge) jam service check ............................................................................................197
Sensor (HPU leading edge) jam service check............................................................................................ 199
HPU motor jam service check ....................................................................................................................200
HPU communication error jam service check ............................................................................................201
Output expander main motor service check..............................................................................................202
Sensor (OE pass through) jam service check..............................................................................................204
Output expander media entrance jam service check.................................................................................208
Output expander diverter jam service check .............................................................................................211
Understanding the printer messages....................................................................................................213
Cartridge, imaging unit mismatch [41.xy]....................................................................................................... 213
Cartridge low [88.xy]....................................................................................................................................... 213
Cartridge nearly low [88.xy]............................................................................................................................213
Cartridge very low, [x] estimated pages remain [88.xy] .................................................................................213
Change [paper source] to [custom string] load [orientation] .........................................................................213
Change [paper source] to [custom type name] load [orientation]................................................................. 214
Change [paper source] to [paper size] load [orientation] ..............................................................................214
Change [paper source] to [paper type] [paper size] load [orientation].......................................................... 214
Check tray [x] connection ...............................................................................................................................214
Close door or insert cartridge .........................................................................................................................215
Close rear door ...............................................................................................................................................215
Complex page, some data may not have printed [39]....................................................................................215
Configuration change, some held jobs were not restored [57] ......................................................................215
Defective flash detected [51]..........................................................................................................................215
Disk must be formatted for use in this device ................................................................................................ 215
Disk near full. Securely clearing disk space..................................................................................................... 216
Empty the hole punch box ..............................................................................................................................216
Error reading USB drive. Remove USB. ...........................................................................................................216
Error reading USB hub. Remove hub. .............................................................................................................216
Imaging unit low [84.xy] ................................................................................................................................. 216
Imaging unit nearly low [84.xy] ......................................................................................................................216
Imaging unit very low, [x] estimated pages remain [84.xy]............................................................................216
Incompatible output bin [x] [59]..................................................................................................................... 217
Incompatible tray [x] [59] ...............................................................................................................................217
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Incorrect paper size, open [paper source] [34] .............................................................................................. 217
Insert hole punch box .....................................................................................................................................217
Insert staple cartridge..................................................................................................................................... 217
Insert Tray [x].................................................................................................................................................. 218
Install bin [x] ................................................................................................................................................... 218
Install Tray [x] .................................................................................................................................................218
Insufficient memory for Flash Memory Defragment operation [37].............................................................. 218
Insufficient memory, some Held Jobs were deleted [37] ...............................................................................218
Insufficient memory, some held jobs will not be restored [37]......................................................................219
Insufficient memory to collate job [37] .......................................................................................................... 219
Insufficient memory to support Resource Save feature [35]..........................................................................219
Load staples ....................................................................................................................................................219
Load [paper source] with [custom string] [paper orientation] .......................................................................219
Load [paper source] with [custom type name] [paper orientation]............................................................... 220
Load [paper source] with [paper size] [paper orientation].............................................................................220
Load [paper source] with [paper type] [paper size] [paper orientation]........................................................220
Load manual feeder with [custom string] [paper orientation] .......................................................................220
Load manual feeder with [custom type name] [paper orientation]...............................................................221
Load manual feeder with [paper size] [paper orientation].............................................................................221
Load manual feeder with [paper type] [paper size] [paper orientation]........................................................221
Maintenance kit low [80.xy] ........................................................................................................................... 221
Maintenance kit nearly low [80.xy] ................................................................................................................221
Maintenance kit very low, [x] estimated pages remain [80.xy]......................................................................222
Memory full [38] ............................................................................................................................................. 222
Network [x] software error [54] ..................................................................................................................... 222
Non‑Lexmark [supply type], see User’s Guide [33.xy] ....................................................................................222
Not enough free space in flash memory for resources [52] ...........................................................................223
PPDS font error [50]........................................................................................................................................ 223
Paper changes needed....................................................................................................................................223
Parallel port [x] disabled [56]..........................................................................................................................223
Reattach bin [x]............................................................................................................................................... 224
Reattach bins [x] – [y] .....................................................................................................................................224
Reinstall missing or unresponsive cartridge [31.xy] ....................................................................................... 225
Reinstall missing or unresponsive fuser [31.xy]..............................................................................................225
Reinstall missing or unresponsive imaging unit [31.xy] ..................................................................................225
Remove defective disk [61].............................................................................................................................225
Remove packaging material, [area name] ......................................................................................................225
Remove paper from all bins............................................................................................................................225
Remove paper from bin [x] .............................................................................................................................226
Remove paper from [linked set bin name] ..................................................................................................... 226
Remove paper from standard output bin.......................................................................................................226
Replace cartridge, 0 estimated pages remain [88.xy]..................................................................................... 226
Replace cartridge, printer region mismatch [42.xy] .......................................................................................226
Replace imaging unit, 0 estimated pages remain [84.xy] ............................................................................... 227
Replace maintenance kit, 0 estimated pages remain [80.xy] .........................................................................227
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Replace roller kit [81.xx] ................................................................................................................................. 227
Replace unsupported cartridge [32.xy] ..........................................................................................................227
Replace unsupported fuser [32.xy].................................................................................................................227
Replace unsupported imaging unit [32.xy] .....................................................................................................227
Restore held jobs? .......................................................................................................................................... 228
Serial port [x] disabled [56]............................................................................................................................. 228
Some held jobs were not restored ................................................................................................................. 228
Standard network software error [54]............................................................................................................228
Standard USB port disabled [56].....................................................................................................................228
Supply needed to complete job......................................................................................................................229
Too many bins attached [58] ..........................................................................................................................229
Too many disks installed [58] ......................................................................................................................... 229
Too many flash options installed [58].............................................................................................................229
Too many trays attached [58]......................................................................................................................... 229
Tray [x] paper size unsupported ..................................................................................................................... 229
Unformatted flash detected [53]....................................................................................................................230
Unsupported disk............................................................................................................................................230
Unsupported option in slot [x] [55] ................................................................................................................230
USB port [x] disabled [56] ...............................................................................................................................230
User attendance messages....................................................................................................................230
User attendance messages (0‑99.99) ............................................................................................................. 230
Toner level sensing error check ......................................................................................................................235
Toner cartridge smart chip error service check ..............................................................................................236
Imaging unit smart chip service check ............................................................................................................236
Fuser unit smart chip service check................................................................................................................ 237
Printer hardware errors........................................................................................................................237
1yy error messages .........................................................................................................................................238
Printhead ID service check.............................................................................................................................. 242
Printhead service check ..................................................................................................................................242
Fuser drive motor service check .....................................................................................................................243
Fuser service check ......................................................................................................................................... 243
LVPS service check ..........................................................................................................................................244
Toner level sensing service check ................................................................................................................... 244
Main drive motor service check...................................................................................................................... 245
Media feeder service check ............................................................................................................................245
Redrive motor service check...........................................................................................................................246
Duplex motor service check............................................................................................................................ 246
Toner add motor service check ......................................................................................................................247
Main cooling fan service check .......................................................................................................................247
Cartridge cooling fan service check ................................................................................................................248
Fuser cooling fan service check ...................................................................................................................... 248
9yy error messages .........................................................................................................................................248
Steps before starting the 9yy service checks ..................................................................................................252
System software error service check .............................................................................................................. 253
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NVRAM mismatch failure service check .........................................................................................................258
RAM memory error service check ..................................................................................................................259
Download emulation cyclic redundancy service check...................................................................................259
Base printer symptoms................................................................................................................................... 260
Network service check.................................................................................................................................... 260
Dead machine service check...........................................................................................................................262
Input/output option hardware errors...................................................................................................263
3yy error messages .........................................................................................................................................263
250/550-sheet transport motor failure service check.................................................................................... 270
250/550-sheet media feeder failure service check ........................................................................................271
250/550-sheet controller board failure service check.................................................................................... 273
HCIT lift drive motor failure service check......................................................................................................274
HCIT lift plate failure service check.................................................................................................................276
HCIT transport motor failure service check ....................................................................................................278
HCOE failure service check .............................................................................................................................280
Mailbox failure service check..........................................................................................................................281
Option tray symptoms ....................................................................................................................................282
250/550-sheet media type error service check ..............................................................................................284
250/550-sheet tray undetected service check ...............................................................................................286
250/550-sheet option undetected service check ........................................................................................... 287
HCIT incorrect media error service check .......................................................................................................287
HCIT media type error service check .............................................................................................................. 289
HCIT undetected service check ....................................................................................................................... 291
HCIT media low undetected service check .....................................................................................................293
Mailbox incorrect bin exit service check.........................................................................................................295
Mailbox undetected service check .................................................................................................................297
Finisher side door error service check ............................................................................................................298
Finisher cartridge error service check ............................................................................................................ 300
Finisher undetected service check..................................................................................................................301
Finisher bin error service check ..................................................................................................................... 302
Finisher door undetected service check ........................................................................................................ 304
Stapler carriage failure service check ............................................................................................................. 305
Finisher bin media present error service check..............................................................................................307
Stuck media on hole puncher service check ...................................................................................................308
Missing or misaligned hole punch service check ............................................................................................ 309
Hole punch box undetected service check .....................................................................................................311
Finisher door (HPU) undetected service check...............................................................................................312
Output expander error service check .............................................................................................................313
Output expander rear door undetected service check................................................................................... 314
Output expander undetected service check...................................................................................................315
Output expander bin error service check .......................................................................................................316
HCOE bin error service check..........................................................................................................................318
HCOE undetected service check ..................................................................................................................... 318
HCOE rear door undetected service check .....................................................................................................319
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Service menus..........................................................................................321
Understanding the printer control panel..............................................................................................321
Using the printer control panel.......................................................................................................................321
Understanding the colors of the Sleep button and indicator lights................................................................ 322
Updating the printer firmware..............................................................................................................322
Menus list..............................................................................................................................................323
Diagnostics menu..................................................................................................................................323
Entering the Diagnostics menu....................................................................................................................... 323
REGISTRATION ................................................................................................................................................ 324
PRINT TESTS ....................................................................................................................................................324
Print Quality Pages (Prt Quality Pgs) .......................................................................................................... 325
HARDWARE TESTS ..........................................................................................................................................325
Panel Test ................................................................................................................................................... 325
Button Test.................................................................................................................................................325
DRAM Test.................................................................................................................................................. 326
Serial Wrap Test ......................................................................................................................................... 326
USB HS Test Mode...................................................................................................................................... 327
DUPLEX TESTS .................................................................................................................................................327
Quick Test...................................................................................................................................................327
Top Margin ................................................................................................................................................. 328
Sensor Test ................................................................................................................................................. 328
Motor Test.................................................................................................................................................. 329
Duplex Feed 1............................................................................................................................................. 329
Duplex Feed 2............................................................................................................................................. 329
INPUT TRAY TESTS ..........................................................................................................................................330
Feed Tests .................................................................................................................................................. 330
Sensor Tests ............................................................................................................................................... 330
OUTPUT BIN TESTS ......................................................................................................................................... 331
Feed Tests .................................................................................................................................................. 331
Feed To All Bins .......................................................................................................................................... 331
Sensor Test ................................................................................................................................................. 331
Diverter Test...............................................................................................................................................331
FINISHER TESTS ............................................................................................................................................... 332
Staple Test .................................................................................................................................................. 332
Hole Punch Test.......................................................................................................................................... 332
Feed Test ....................................................................................................................................................332
Finisher Sensor Test ...................................................................................................................................333
BASE SENSOR TEST..........................................................................................................................................333
DEVICE TESTS .................................................................................................................................................. 334
Quick Disk Test ........................................................................................................................................... 334
Disk Test/Clean........................................................................................................................................... 334
Flash Test....................................................................................................................................................334
PRINTER SETUP ............................................................................................................................................... 335
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Defaults ...................................................................................................................................................... 335
Printed Page Count.....................................................................................................................................336
Permanent Page Count (Perm page count)................................................................................................336
Processor ID................................................................................................................................................336
Engine Setting [x] ....................................................................................................................................... 336
Edge to Edge............................................................................................................................................... 336
Parallel Strobe Adjustment (Par 1 Strobe Adj) ...........................................................................................336
EP SETUP ......................................................................................................................................................... 337
EP Defaults ................................................................................................................................................. 337
Fuser Temperature (Fuser Temp)...............................................................................................................337
Fuser Page Count ....................................................................................................................................... 337
Warm Up Time ...........................................................................................................................................337
Transfer ...................................................................................................................................................... 338
Print Contrast ............................................................................................................................................. 338
Charge Roll ................................................................................................................................................. 338
Gap Adjust .................................................................................................................................................. 338
Automatic Darkness Adjust (Auto Dark Adj) ..............................................................................................338
REPORTS ......................................................................................................................................................... 339
Menu Settings Page....................................................................................................................................339
Installed Licenses........................................................................................................................................339
EVENT LOG......................................................................................................................................................339
Display Log ................................................................................................................................................. 339
Print Log ..................................................................................................................................................... 340
Clear Log..................................................................................................................................................... 340
Exit Diags......................................................................................................................................................... 340
Configuration menu..............................................................................................................................340
Entering the Configuration menu ................................................................................................................... 341
Roller Kit Counter Value..................................................................................................................................342
Reset Roller Kit Counter.................................................................................................................................. 342
Print Quality Pages.......................................................................................................................................... 342
Reports ........................................................................................................................................................... 343
Menu Settings Page....................................................................................................................................343
Event Log ....................................................................................................................................................343
Size sensing .....................................................................................................................................................343
Panel Menus ................................................................................................................................................... 344
PPDS Emulation ..............................................................................................................................................344
Download Emuls .............................................................................................................................................344
Safe Mode....................................................................................................................................................... 344
Factory Defaults..............................................................................................................................................345
Energy Conserve ............................................................................................................................................. 345
Paper Prompts ................................................................................................................................................ 345
Envelope Prompts........................................................................................................................................... 346
Action for Prompts.......................................................................................................................................... 346
Jobs on Disk ....................................................................................................................................................347
Disk Encryption ...............................................................................................................................................347
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Erase All Information on Disk.......................................................................................................................... 347
Wipe All Settings............................................................................................................................................. 348
Font Sharpening..............................................................................................................................................348
Require Standby.............................................................................................................................................. 348
A5 Loading ...................................................................................................................................................... 348
UI Automation ................................................................................................................................................ 349
LES Applications ..............................................................................................................................................349
Key Repeat Initial Delay ..................................................................................................................................349
Key Repeat Rate.............................................................................................................................................. 350
Wiper Message ............................................................................................................................................... 350
Clear Supply Usage History ............................................................................................................................. 350
Clear Custom Status........................................................................................................................................350
USB Speed....................................................................................................................................................... 350
Automatically Display Error Screens ............................................................................................................... 351
USB PnP .......................................................................................................................................................... 351
Entering invalid engine mode................................................................................................................351
Entering recovery mode........................................................................................................................352
Accessing the Network SE menu...........................................................................................................352
Service Engineer menu..........................................................................................................................352
Accessing the service engineer (SE) menu...................................................................................................... 352
Service engineer (SE) menu ............................................................................................................................ 352
Repair information...................................................................................355
Removal precautions.............................................................................................................................355
Handling ESD‑sensitive parts ..........................................................................................................................355
Controller board/control panel replacement .................................................................................................356
Restoring the printer configuration after replacing the controller board ...................................................... 357
eSF solutions backup ...................................................................................................................................... 359
Ribbon cable connectors ................................................................................................................................360
Zero Insertion Force (ZIF) connectors ........................................................................................................ 360
Horizontal top contact connector ..............................................................................................................361
Horizontal bottom contact connector........................................................................................................ 364
Vertical mount contact connector .............................................................................................................367
Horizontal sliding contact connector ......................................................................................................... 370
Low Insertion Force (LIF) connector...........................................................................................................373
Adjustments..........................................................................................................................................374
Media aligner roller adjustment ..................................................................................................................... 376
Polygon printhead mechanical registration adjustment ................................................................................ 377
Removal procedures.............................................................................................................................380
Front side removals...............................................................................................................................380
Duplex exit diverter removal ..........................................................................................................................381
Front door removal......................................................................................................................................... 383
Inner guide deflector removal ........................................................................................................................384
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Laser printhead removal................................................................................................................................. 386
Left inner cover removal................................................................................................................................. 390
Media aligner roller removal ..........................................................................................................................392
Media turn guide removal .............................................................................................................................. 394
Media vertical guide removal ......................................................................................................................... 395
MPF feeder lift plate removal .........................................................................................................................397
MPF pick roller removal.................................................................................................................................. 400
MPF solenoid removal .................................................................................................................................... 402
MPF tray removal ........................................................................................................................................... 404
Right inner cover removal ..............................................................................................................................406
Sensor (input) removal ................................................................................................................................... 407
Sensor (toner density) removal ...................................................................................................................... 408
Transfer roller left arm with cable removal .................................................................................................... 410
Transfer roller right arm removal ...................................................................................................................411
Transfer roller removal ................................................................................................................................... 414
4.3‑inch tilting display removal.......................................................................................................................417
7‑inch tilting display removal.......................................................................................................................... 419
Control panel removal (2.4‑inch screen) ........................................................................................................ 422
Control panel removal (4.3‑inch screen, 7‑inch screen) ................................................................................. 428
Control panel board (2.4‑inch tilting display) removal ................................................................................... 434
Control panel board (4.3‑inch tilting display) removal ................................................................................... 437
Control panel board (7‑inch tilting display) removal (MS812de) ................................................................... 440
Control panel front cover removal ................................................................................................................. 443
Control panel latch removal ...........................................................................................................................445
Control panel left bezel removal .................................................................................................................... 446
Left control panel hinge removal.................................................................................................................... 447
Right control panel hinge removal..................................................................................................................450
Rear side removals................................................................................................................................453
Rear lower cover removal............................................................................................................................... 454
Rear door removal .......................................................................................................................................... 456
Duplex motor removal.................................................................................................................................... 457
Fuser removal .................................................................................................................................................459
Fuser access door removal ............................................................................................................................. 461
Left frame pivot removal ................................................................................................................................ 462
Output bin sensor cover removal ................................................................................................................... 463
Right frame pivot removal .............................................................................................................................. 464
Sensor (rear door interlock) removal..............................................................................................................465
Top side removals.................................................................................................................................465
Top cover removal .......................................................................................................................................... 466
Sensor (standard bin full) removal .................................................................................................................466
Standard bin cover removal............................................................................................................................467
Upper redrive motor removal.........................................................................................................................469
Upper redrive removal....................................................................................................................................471
Bottom side removals...........................................................................................................................472
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Duplex removal...............................................................................................................................................473
Duplex front flap removal............................................................................................................................... 475
Duplex rear flap removal ................................................................................................................................476
Left frame extension removal.........................................................................................................................477
Media tray removal ........................................................................................................................................ 479
Media size actuator removal ..........................................................................................................................480
Pick roller assembly removal .......................................................................................................................... 482
Right frame extension.....................................................................................................................................483
Sensor (duplex path) removal......................................................................................................................... 484
Sensor (tray 1 media out) removal ................................................................................................................. 485
Separator roller assembly removal................................................................................................................. 487
Left side removals.................................................................................................................................488
Left cover removal ..........................................................................................................................................489
Controller board removal ...............................................................................................................................492
Controller board access cover removal ..........................................................................................................493
Controller board access shield removal.......................................................................................................... 494
Fuser drive motor removal ............................................................................................................................. 494
Main cooling fan removal ...............................................................................................................................496
Main drive motor removal.............................................................................................................................. 497
Media feeder removal ....................................................................................................................................498
PCBA housing removal.................................................................................................................................... 500
Sensor (control panel interlock) removal .......................................................................................................501
Sensor (pick roller position) removal.............................................................................................................. 502
Toner add motor removal............................................................................................................................... 503
Right side removals...............................................................................................................................504
Right cover removal........................................................................................................................................505
Cartridge cooling fan removal ........................................................................................................................507
Duplex cooling fan removal ............................................................................................................................ 508
Fuser cooling fan removal...............................................................................................................................509
HVPS removal .................................................................................................................................................510
LVPS removal .................................................................................................................................................. 511
250/550-sheet media tray option removals..........................................................................................514
250/550-sheet media tray and drawer assembly removal............................................................................. 514
Media tray separation roller removal............................................................................................................. 514
Media tray assembly removal......................................................................................................................... 515
Media tray front cover removal......................................................................................................................515
Drawer pick roller removal ............................................................................................................................516
Sensor (pick roll position) removal ................................................................................................................516
Drawer assembly rear cover removal .............................................................................................................517
Drawer assembly left cover removal .............................................................................................................. 518
Drawer controller PCBA removal.................................................................................................................... 519
Drawer upper interface cable removal...........................................................................................................520
Drawer lower interface cable removal ...........................................................................................................521
Drawer media feeder removal ....................................................................................................................... 522
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Drawer transport motor removal ................................................................................................................... 524
Sensor (pick) removal .....................................................................................................................................525
Sensor (drawer pass through) removal .......................................................................................................... 527
High capacity input tray option removals.............................................................................................530
High capacity input tray option removal ........................................................................................................530
HCIT removal ..................................................................................................................................................531
HCIT drawer assembly removal ......................................................................................................................531
HCIT separator roller assembly removal.........................................................................................................532
HCIT media guide removal..............................................................................................................................532
HCIT front cover removal................................................................................................................................ 533
HCIT pick roller assembly removal.................................................................................................................. 535
HCIT rear cover removal ................................................................................................................................. 536
HCIT left cover removal .................................................................................................................................. 537
HCIT right cover removal ................................................................................................................................539
HCIT controller PCBA removal ........................................................................................................................ 541
HCIT top cover assembly removal ..................................................................................................................542
HCIT lift drive motor removal ......................................................................................................................... 544
HCIT interface cable removal..........................................................................................................................546
Sensor (HCIT media low) with flag removal.................................................................................................... 547
Sensor (HCIT pick roller position) removal .....................................................................................................548
Sensor (HCIT pick) removal............................................................................................................................. 550
HCIT media feeder removal ............................................................................................................................551
Output expander option removals........................................................................................................554
Output expander option removal ...................................................................................................................554
Output expander top cover removal ..............................................................................................................554
Output expander rear door removal ..............................................................................................................555
Output expander sensor cover removal .........................................................................................................557
Output expander bin full flag removal............................................................................................................557
Sensor (media bin full) with flag removal .......................................................................................................557
Output expander right cover removal ............................................................................................................558
Output expander left cover removal ..............................................................................................................560
Output expander controller PCBA removal .................................................................................................... 562
Lower interface cable removal .......................................................................................................................563
Upper interface cable removal ....................................................................................................................... 564
Spring with string removal..............................................................................................................................566
Output expander option latch removal ..........................................................................................................567
Output expander diverter motor removal...................................................................................................... 568
Output expander diverter plunger assembly removal....................................................................................568
Output expander drive gear removal .............................................................................................................570
Output expander main motor removal ..........................................................................................................571
Sensor (OE rear door interlock) removal ........................................................................................................573
Sensor (OE diverter plunger HP) removal.......................................................................................................575
Output expander diverter spring removal......................................................................................................576
Output expander diverter removal................................................................................................................. 577
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Output expander drive belt removal ..............................................................................................................579
Output expander belt tensioner removal .......................................................................................................579
Output expander bin removal ........................................................................................................................ 580
Sensor (OE pass through) removal .................................................................................................................581
High capacity output expander option removals..................................................................................584
High capacity output expander option removal .............................................................................................584
HCOE top cover removal.................................................................................................................................584
HCOE rear door removal................................................................................................................................. 585
HCOE sensor cover removal ...........................................................................................................................586
HCOE bin full flag removal .............................................................................................................................. 587
Sensor (HCOE media bin full) with flag removal .............................................................................................587
HCOE right cover removal............................................................................................................................... 588
HCOE left cover removal................................................................................................................................. 589
HCOE controller PCBA removal.......................................................................................................................591
HCOE lower interface cable removal .............................................................................................................. 593
HCOE upper interface cable removal.............................................................................................................. 594
HCOE option latch removal............................................................................................................................. 594
HCOE diverter motor removal ........................................................................................................................ 595
Sensor (HCOE tray HP) removal ...................................................................................................................... 596
HCOE tray spring removal............................................................................................................................... 597
HCOE tray pinion removal ..............................................................................................................................598
Sensor (HCOE rear door interlock) removal.................................................................................................... 599
HCOE belt tensioner removal ......................................................................................................................... 601
HCOE drive belt removal.................................................................................................................................602
HCOE diverter plunger assembly removal ...................................................................................................... 604
HCOE main drive gear assembly removal .......................................................................................................605
HCOE main motor removal ............................................................................................................................. 607
Sensor (HCOE diverter HP) removal................................................................................................................ 609
HCOE top diverter spring removal .................................................................................................................. 611
HCOE top diverter removal.............................................................................................................................612
HCOE tray shaft removal................................................................................................................................. 614
HCOE bin removal........................................................................................................................................... 615
Sensor (HCOE pass through) removal.............................................................................................................618
Staple finisher option removals............................................................................................................621
Staple finisher option removal .......................................................................................................................621
Stapler rear door removal............................................................................................................................... 622
Stapler right cover removal ............................................................................................................................624
Stapler door close limit switch removal..........................................................................................................626
Sensor (cartridge door interlock) removal......................................................................................................627
Stapler carriage assembly removal .................................................................................................................628
Stapler left cover removal ..............................................................................................................................630
Stapler cartridge access door removal ........................................................................................................... 632
Sensor (throat media present) removal .........................................................................................................632
Stapler top cover removal ..............................................................................................................................635
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Stapler spring with string removal.................................................................................................................. 637
Stapler option latch removal ..........................................................................................................................638
Stapler tray spring removal.............................................................................................................................639
Stapler tray link assembly removal .................................................................................................................640
Sensor (stapler rear door interlock) removal.................................................................................................. 642
Sensor (paddle motor HP) removal ................................................................................................................643
Media stack flap (right) removal.....................................................................................................................643
Media stack flap (left) removal .......................................................................................................................645
Sensor (right tamper motor HP) removal .......................................................................................................647
Sensor (left tamper motor HP) removal .........................................................................................................649
Standard output bin LED removal...................................................................................................................652
Sensor (finisher bin media present) removal..................................................................................................653
Tamper assembly removal..............................................................................................................................654
Tamper motor (right) removal........................................................................................................................656
Tamper motor (left) removal .......................................................................................................................... 656
Tamper drive belt removal ............................................................................................................................. 657
Stapler output bin LED removal......................................................................................................................658
Paddle drive motor removal ........................................................................................................................... 660
Stapler lower interface cable removal............................................................................................................661
Stapler controller PCBA removal .................................................................................................................... 663
Stapler main motor removal........................................................................................................................... 664
Stapler diverter motor removal ...................................................................................................................... 666
Stapler diverter plunger assembly removal.................................................................................................... 667
Stapler drive gear assembly removal..............................................................................................................668
Sensor (bin full send) removal ........................................................................................................................ 669
Sensor (bin full receive) removal ....................................................................................................................670
Media pusher assembly removal ....................................................................................................................672
Stapler feed roll removal ................................................................................................................................672
Stapler chute assembly removal.....................................................................................................................674
Sensor (stapler pass through) removal...........................................................................................................677
Stapler ejector motor assembly removal........................................................................................................678
Sensor (stapler ejector HP) removal ............................................................................................................... 681
Sensor (media pusher HP) removal ................................................................................................................ 684
Sensor (stapler diverter plunger HP) removal ................................................................................................ 686
Mailbox option removals......................................................................................................................688
Mailbox option removal .................................................................................................................................688
Mailbox top cover removal............................................................................................................................. 688
Mailbox rear door removal .............................................................................................................................689
Mailbox right cover removal...........................................................................................................................691
Mailbox top bin cover with bail removal ........................................................................................................692
Mailbox spring with string removal ................................................................................................................ 693
Mailbox solenoid removal ..............................................................................................................................694
Mailbox left cover removal............................................................................................................................. 696
Mailbox option latch removal......................................................................................................................... 697
Sensor (mailbox rear door interlock) removal ................................................................................................697
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Mailbox diverter plunger assembly removal ..................................................................................................698
Mailbox main drive gear removal ................................................................................................................... 703
Mailbox main motor removal .........................................................................................................................706
Mailbox controller PCBA removal................................................................................................................... 707
Sensor (mailbox diverter plunger HP) removal...............................................................................................708
Mailbox lower interface cable removal .......................................................................................................... 710
Mailbox upper interface cable removal.......................................................................................................... 712
Mailbox diverter motor removal ....................................................................................................................712
Mailbox media bin full flag removal ............................................................................................................... 714
Sensor (mailbox bin full receive) removal ......................................................................................................715
Mailbox belt removal......................................................................................................................................718
Mailbox output bin LED assembly removal ....................................................................................................720
Mailbox top diverter removal.........................................................................................................................723
Mailbox middle diverter removal ................................................................................................................... 728
Mailbox top diverter spring removal .............................................................................................................. 729
Sensor (mailbox pass through) removal ......................................................................................................... 733
Staple, hole punch finisher option removals.........................................................................................738
Staple, hole punch finisher option removal....................................................................................................738
Stapler cartridge access door removal ........................................................................................................... 739
Hole punch box removal................................................................................................................................. 739
Staple, hole punch left cover removal ............................................................................................................739
Staple, hole punch right cover removal..........................................................................................................741
Sensor (cartridge door interlock) removal......................................................................................................742
Stapler door close limit switch removal..........................................................................................................743
Stapler carriage assembly removal .................................................................................................................746
Sensor (throat media present) removal .........................................................................................................747
Staple, hole punch latch removal ................................................................................................................... 749
Stapler controller PCBA removal .................................................................................................................... 749
Stapler main motor removal........................................................................................................................... 750
Stapler paddle motor removal........................................................................................................................751
Sensor (paddle motor HP) removal ................................................................................................................752
Stapler diverter motor removal ...................................................................................................................... 753
Stapler diverter plunger assembly removal.................................................................................................... 754
Stapler drive gear assembly removal..............................................................................................................755
Sensor (bin full send) removal ........................................................................................................................ 756
Sensor (bin full receive) removal ....................................................................................................................757
Staple, hole punch lower interface cable removal ......................................................................................... 759
Media pusher assembly removal ....................................................................................................................759
Standard output bin LED removal...................................................................................................................760
Sensor (finisher bin media present) removal..................................................................................................761
Staple, hole punch top cover removal ............................................................................................................762
Sensor (right tamper motor HP) removal .......................................................................................................763
Sensor (left tamper motor HP) removal .........................................................................................................765
Stapler tamper assembly removal ..................................................................................................................767
Tamper motor (right) removal........................................................................................................................769
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Tamper motor (left) removal .......................................................................................................................... 770
Tamper drive belt removal ............................................................................................................................. 771
Stapler output bin LED removal......................................................................................................................772
Staple, hole punch tray link tension spring removal.......................................................................................774
Staple, hole punch tray link removal ..............................................................................................................774
Sensor (hole punch box present) removal......................................................................................................775
Sensor (HPU rear door interlock) removal......................................................................................................776
Component locations...............................................................................779
Exterior locations..................................................................................................................................779
Front view .......................................................................................................................................................779
Rear view ........................................................................................................................................................ 781
Connectors............................................................................................................................................782
Controller board ............................................................................................................................................. 782
Maintenance............................................................................................791
Inspection guide....................................................................................................................................791
Scheduled maintenance........................................................................................................................793
Fuser maintenance kits...................................................................................................................................793
Replacing fuser maintenance kits ................................................................................................................... 794
Identifying the type of fuser used in the printer ............................................................................................795
Resetting the Roller Kit counter...................................................................................................................... 796
Preventive maintenance.......................................................................................................................797
Device‑specific preventive maintenance........................................................................................................ 797
Lubrication specification.......................................................................................................................797
Cleaning the printer..............................................................................................................................797
Cleaning the printer ........................................................................................................................................ 797
Emptying the hole punch box ......................................................................................................................... 798
Parts catalog............................................................................................800
Legend...................................................................................................................................................801
Assembly 1: Covers................................................................................................................................803
Assembly 2: Paper path.........................................................................................................................807
Assembly 3: Fusers................................................................................................................................809
Assembly 4: Electronics.........................................................................................................................811
Assembly 5: Drive motors.....................................................................................................................815
Assembly 6: Duplex...............................................................................................................................817
Assembly 7: Frame................................................................................................................................819
Assembly 8: Control panel.....................................................................................................................821
Assembly 9: Paper tray..........................................................................................................................825
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Assembly 10: Input options...................................................................................................................827
Assembly 11: 250-sheet tray option......................................................................................................829
Assembly 12: 550-sheet tray option......................................................................................................831
Assembly 13: High capacity input tray option 1....................................................................................833
Assembly 14: High capacity input tray option 2....................................................................................835
Assembly 15: Output options................................................................................................................837
Assembly 16: Output expander option 1..............................................................................................839
Assembly 17: Output expander option 2..............................................................................................841
Assembly 18: Output expander option 3..............................................................................................843
Assembly 19: Output expander option 4..............................................................................................845
Assembly 20: High capacity output expander option 1.........................................................................847
Assembly 21: High capacity output expander option 2.........................................................................849
Assembly 22: High capacity output expander option 3.........................................................................851
Assembly 23: High capacity output expander option 4.........................................................................853
Assembly 24: Staple finisher option 1...................................................................................................855
Assembly 25: Staple finisher option 2...................................................................................................857
Assembly 26: Staple finisher option 3...................................................................................................859
Assembly 27: Staple finisher option 4...................................................................................................861
Assembly 28: Mailbox option 1.............................................................................................................863
Assembly 29: Mailbox option 2.............................................................................................................865
Assembly 30: Mailbox option 3.............................................................................................................867
Assembly 31: Staple, hole punch finisher option 1...............................................................................869
Assembly 32: Staple, hole punch finisher option 2...............................................................................871
Assembly 33: Staple, hole punch finisher option 3...............................................................................873
Assembly 34: Staple, hole punch finisher option 4...............................................................................875
Assembly 35: Power cords....................................................................................................................877
Assembly 36: Miscellaneous.................................................................................................................879
Appendix A: Printer specifications............................................................881
Power specifications..............................................................................................................................881
Operating clearances.............................................................................................................................882
Acoustics...............................................................................................................................................882
Environment..........................................................................................................................................882
Processor...............................................................................................................................................883
Security reset jumper............................................................................................................................883
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