Dell 3335DN- Manuals

vi Service Manual Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Table of contents vii Print SE Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

viii Service Manual UICC cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65USB cable mount bracket removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66O...

Table of contents ix Assembly 2: Imaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Assembly 3: Tray assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Notices and safety information xi Notices and safety information The following laser notice labels may be affixed to this printer. Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified a...

xii Service Manual Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condicione...

Notices and safety information xiii Laserilmoitus Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) -lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi. Luokan I lasertuotteita ei pidetä haitallisina. Tulostim...

xiv Service Manual Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’I...

Lithium warning Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has b...

Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für ...

Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. • La informació pel manteniment d’aquest prod...

Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment, as well as general environmenta...

General information 1-1 1. General information n A4, 25ppm on legal). Maintenance approach The diagnostic information in this manual leads to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, and service checks to determine the symptom and repair the failure...

1-2 Service Manual Print engine specifications Memory Print quality settings Item Standard memory 128MB 128MB Maximum memory 640MB 640MB Optional memory 128MB DDR SDRAM unbuffered DIMMS ✔ ✔ 256MB DDR SDRAM unbuffered DIMMS ✔ ✔ 512MB DDR SDRAM unbuffered DIMMS ✔ ✔ Optional flash memory 256 MB via fla...

General information 1-3 Environment Specified operating environment Operating temperature range - 16 to 32 degrees C (60 to 90 degrees F Humidity - 8 to 80% Relative humidity Altitude 0 to 3048 meters (10,000 ft) Dimensions Height - 23.3 in (297mm) Width - 20.87 in (530 mm) Depth - 15.5 in (394 mm) ...

1-4 Service Manual Media trays and supply capacity Item Available input trays Integrated 250-sheet tray ✔ ✔ 50-sheet MP feeder ✔ ✔ 1-sheet manual feed slot x x Optional input sources 250-sheet drawer ✔ ✔ 550-sheet drawer ✔ ✔ Maximum input sheet capacity 850 (excluding envelopes) 850 (excluding envel...

General information 1-5 Types of print media Note: Ensure trays are properly loaded. Never mix media types within a tray. Source Sizes Types Weight Input capacity* (sheets) Input tray 1 (250-sheet tray) A4, A5, A6,JIS¹-B5, letter, legal, executive, oficio (Mexico)², folio², statement Plain paper, re...

1-6 Service Manual Media guidelines Paper characteristics The following paper characteristics affect print quality and reliability. Consider these characteristics when evaluating new paper stock. • Weight —The printer can automatically feed paper weights from 60 to 176 g/m 2 (16 to 47 lb bond) grain...

General information 1-9 Digital imaging specifications General specifications ADF Scan speed Simplex ADF - Up to 25 ppm Duplex ADF - Up to 35 ppm (page sides) ADF Document handling ADF input capacity - 50 sheets. ADF output capacity - 50 sheets. ADF document width - 4.9’’ (125mm) to 8.5’’ (216mm) AD...

1-10 Service Manual Storage environments (unpacked) • Temperature - 0° to 40°C • Humidity - 5 to 80% relative humidity Tilt This device should operate within the stated parameters when it is level within 10mm from front to back and 10mm side to side. Scan and copy specific specifications Scan Resolu...

1-12 Service Manual Fax specifications Phone network connectivity Fax resolutions Miscellaneous FAX specifications Phone networks types suppor ted PSTN or analog PABX (RJ-11) ITU COMPATIBILITY Standard Resolution Fine Superfine Ultrafine Coding Group 3/ECM 8 x 3.85 pels/mm (200X100dpi) (204x98) 8 x ...

General information 1-13 Tools The removal and adjustment procedures require the following tools and equipment: • Spring hook • Needle nose pliers • Volt-ohmmeter • #1 and #2 Phillips screwdriver • Slotted screwdriver

1-14 Service Manual Acronyms ac Alternating Current ACM Autocompensator Mechanism (or paper feed) ADF Automatic document feeder AFE Analog front end AIO All-In-One APS Automatic Paper Size ASIC Application Specific Integrated Circuit BLDC Brushless DC Motor BOR Black Only Retract CCD Charge-Couple D...

Diagnostics information 2-1 2. Diagnostics information Start CAUTION: Unplug power from the printer before connecting or disconnecting any cable, assembly, or electronic card. This is a precaution for personal safety and to prevent damage to the printer. Use the service error code, user status messa...

2-2 Service Manual Symptom tables POST symptom table Note: Investigate any displayed codes before proceeding with these symptoms. For example, a missing toner cartridge will prevent POST from completing. Symptom Action The main motor, cooling fan, and fuser do not come on. See “Cover interlock switc...

Diagnostics information 2-3 Printer symptom table Symptom Action Touchscreen displays upside down Replace the display keypad. Fan noisy or fan not working. See “Cooling fan service check” on page 2-37 . Fuser parts melted. See “LVPS/HVPS service check” on page 2-39 . Toner not fused to the media. Se...

Diagnostics information 2-5 Overview of the operator panel and menus The use of the buttons and the layout of the display panel are described in the following table. Item Description 1 Display View scanning, copying, faxing, and printing options as well as status and error messages. 2 Keypad Enter n...

Diagnostics information 2-7 Understanding the home screen After the printer is turned on and a short warm-up period occurs, the display shows the following basic screen which is referred to as the home screen. Use the home screen buttons to initiate an action such as copying, faxing, or scanning; to...

Diagnostics information 2-9 Using the touch-screen buttons Note: Depending on your options and administrative setup, your screens and buttons may vary from those shown. Sample touch screen Button Function Home Returns to the home screen Scroll down Opens a drop-down list Left scroll decrease Scrolls...

2-10 Service Manual Other touch-screen buttons Right arrow Scrolls right Submit Saves a value as the new user default setting Back Navigates back to the previous screen Button Function Down arrow Moves down to the next screen Up arrow Moves up to the next screen Unselected radio button This is an un...

2-12 Service Manual Diagram of the printer menus The diagram shows the menu index on the operator panel and the menus and items available under each menu. Not all menus or selections will be available in all situations. These are accessed through the driver. Paper Menu Default SourcePaper Size/TypeP...

Diagnostics information 2-13 Messages and error codes User attendance messages The printer control panel displays messages describing the current state of the printer and indicates possible printer problems that must be resolved. This topic provides a list of all printer messages, explains what they...

2-14 Service Manual Held jobs may not be restored (Insufficient Memory 37) This message is only posted once after the firmware has tried to restore all of the jobs on disk, regardless of the number of held jobs that were not restored. There are three versions of this IR, depending upon cause. IRHeld...

Diagnostics information 2-15 Load Manual < type > < size > Printer does not detect media meeting the description < type > and < size > in the single sheet feeder (manual feeder). The following actions can be taken: • Load paper and the job continues.• press Select ( ), and ch...

2-20 Service Manual Cartridge error messages Paper jam error codes (200-series) Note: The Event log (See “EVENT LOG” on page 3-32 ) will list any of these errors that have occurred. Repeating jams or jam messages can be caused by any of the following: • Faulty/contaminated pick solenoids or worn cam...

Diagnostics information 2-23 201.25 Exit sensor never made by leading edge of media when feeding out the media that was detected during warm-up. Remove the toner cartridge/PC kit and check for obstructions between the input sensor and the fuser. if the media continues to stop at the entrance or in t...

2-26 Service Manual Service error codes Service error codes are generally non-recoverable except in an intermittent condition when the printer can be put into POR to temporarily recover from the error condition. Error Description Action 8XX Scanner service errors 840.01 Scanner disabled The scanner ...

Diagnostics information 2-31 Fax error codes 975.xx Unrecognizable network Call the next level of support. 976.xx Unrecoverable software error in network port 978.xx Bad checksum while programming network port 979.xx Flash parts failed while programing network port Other errors 980.xx Engine experie...

Diagnostics information 2-35 Service checks Service checks which involve measuring voltages on the LVPS/HVPS (low voltage power supply/high voltage power supply board) should be performed with the printer positioned on its back side. Note: When making voltage readings, always use frame ground unless...

2-36 Service Manual Engine board service check Engine board service check FRU Action Engine board assembly POST (Power-On Self Test) Note: The printer should complete POST in approximately 45 seconds. If the printer fails to display lights or activate the drive motor, fuser, or fan, then check the f...

2-38 Service Manual Dead machine service check CAUTION: Check the AC line voltage. The voltage should be within the following limits: • 100 V ac (volts alternating current)-127 V ac for the 110 V printer • 200 V ac-240 V ac for the 220 V printer FRU Action LVPS/HVPS Unplug the printer. Remove the LV...

Diagnostics information 2-39 Fuser service check When toner is partially fused to the media, it is usually caused by low fuser temperature. The line voltage to the printer must be within the following limits: • 100 V ac-127 V ac for the 110 V model printer • 200 V ac-240 V ac for the 220 V model pri...

2-40 Service Manual Main motor service check FRU Action Main motor gear driveMain motor cableLVPS/HVPSEngine board Warning: Do not replace the engine board and controller board at the same time. Each board contains the printer settings. When either of these boards is new, it obtains the settings fro...

Diagnostics information 2-41 Networking service check Note: Before starting this service check, print out the network setup page. This page is found under Menu - Reports - Network Setup Page. Consult the network administrator to verify that the physical and wireless network settings displayed on the...

Diagnostics information 2-43 Operator panel service check Inspect the operator panel cable for damage. Make sure the cable is plugged in securely. Run POST, and check each light for proper operation. See “Power–On Self Test (POST) sequence” on page 2-1 . Paper feed service checks Paper jam error ind...

Diagnostics information 2-45 Media skews Media “trees,” wrinkles, stacks poorly, or curls Engine boardP/U and manual feed solenoid ASM Check the stairway cables to verify they are properly connected to the engine board at connectors J500 and J501, and on the controller board at connectors J26 and J2...

2-46 Service Manual Option card service check USB port service check 1. Perform a print test to make sure the printer prints correctly. Verify that the indicator light is on, then print the menu settings by Menu Settings Page from the Reports Menu in the menus. 2. Be sure the printer USB cable is de...

Diagnostics information 2-47 Print quality service checks Note: Ensure the cover closes tightly. A gap in the opening may allow light to expose the photoconductor, resulting in a ‘dirty’ print. Extreme environmental conditions, temperatures, and humidity will affect the print quality. Using print qu...

Diagnostics information 2-51 Solving print quality problems Note: Refer to the print defects guide at the end of the manual for repeating defects. Print quality problems Problem Cause / action Light or blurred characters. Light print See “Light print” on page 2-50 . The toner cartridge may be gettin...

2-52 Service Manual Toner smears or rubs off the page. • Toner is not being fused to the paper. Replace the fuser.• Change the media texture setting in the driver. If special media is being used, such as card stock or labels, then be sure to select the correct media type. • Try a different kind of p...

Diagnostics information 2-53 The printer is on and indicates ready, but nothing prints. • Make sure the parallel or USB cable is not damaged and is firmly plugged into the connector on the back of the printer. • Make sure the toner cartridge assembly is installed properly.• Print the menu page using...

Diagnostics information 2-55 Tray 2 service check 840.xx service check FRU Action Tray 2 Turn the printer off. Separate the printer from Tray 2. Turn the printer on and check the voltages on connector J28 on the engine board. Pins 1, 4: 3.3 V Pin 2: 24 V Pin 6: Ground If the voltages are incorrect, ...

2-58 Service Manual Flatbed home position service check Step Questions / actions Yes No 1 POR the MFP. Does the CCD move and return to the home position? Problem solved. Go to step 2. 2 Perform the home position sensor test. Go to “Scanner Tests” on page 3-25 . Is the sensor working properly? Go to ...

2-60 Service Manual ADF paper jam service check Note: This service check should be used if the paper feeds and jams in the ADF. If the paper is not feeding into the ADF see “ADF feed errors service check” on page 2-61 . Step Questions / actions Yes No 1 If the ADF is multi-feeding, check for dirt on...

Diagnostics information 2-61 ADF feed errors service check Step Questions / actions Yes No 1 If the ADF is multi-feeding, check for dirt on the ADF separator pad and ADF separator rollers. Are they dirty? Clean them with a lint free cloth and isopropyl alcohol. Replace the separator pad and ADF pick...

2-62 Service Manual ADF Duplex service check Step Questions / actions Yes No 1 Perform sensor 1, and sensor 2 sensor tests. Go to “Scanner Tests” on page 3-25 . Are the sensors working properly? Go to step 2. Go to step 3. 2 Check the ADF sensor actuators to see if they are dirty or jamming. Are the...

Diagnostics information 2-63 Modem / fax card service check Step Questions / actions Yes No 1 Is the phone line properly connected to the modem card and the wall jack? Go to step 3. Go to step 2. 2 Properly connect the phone line to the modem card and wall jack. Did this fix the problem? Problem res...

2-64 Service Manual Fax transmission service check Note: Before performing this service check, verify that the correct country code for the MFP is selected. This setting must match the country in which the MFP is used to transmit and receive faxes. If the setting is wrong, the modem settings can be ...

Diagnostics information 2-65 15 Adjust the “Transmit Level” setting in the SE menu. Press **411 to enter the SE menu, enter Modem settings, and select “Transmit Level”. Test by adjusting the transmitted signal strength by decreasing/increasing the ‘Transmit Level’ setting in steps of 1db. For exampl...

2-66 Service Manual Fax reception service check Step Questions / actions Yes No 1 Is the phone line properly connected to the modem card and the wall jack? Go to step 3. Go to step 2. 2 Properly connect the phone line to the modem card and wall jack. Did this fix the problem? Problem resolved. Go to...

2-68 Service Manual Escalating a fax issue to second-level support Before contacting the second-level support, go to the SE menu on the MFP.and generate a Fax error file. This file contains machine settings information and debug information that will help second-level support determine the cause of ...

Diagnostic aids 3-1 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. To run the p...

3-2 Service Manual Configuration menu (CONFIG MENU) Available menus Note: Menus may vary depending on the features and options of the printer. Maintenance Count Value See “Maintenance Count Value (Maint Cnt Value)” on page 3-3 . Reset Maintenance Count See “Reset Maintenance Counter” on page 3-3 . R...

Diagnostic aids 3-3 Maintenance Count Value (Maint Cnt Value) This setting enables you to view the current maintenance count value of each maintenance kit. After selecting this item, you can choose a specific kit in order to view its current maintenance count value. To return to the Configuration Me...

3-4 Service Manual Reset Photoconductor Maintenance Counter (Reset PC Cnt) This setting resets the photoconductor kit page counter and clears any warnings or photoconductor exhausted messages. This operation should be performed only after a new photoconductor unit has been installed. USB Scan to Loc...

3-6 Service Manual Factory Defaults Warning: This operation cannot be undone. This setting enables you to restore all of the printer’s settings to the base printer settings, the network settings, or To restore the Factory Default settings: 1. Touch Factory Defaults from the Configuration Menu. 2. To...

Diagnostic aids 3-7 Num Pad Job Assist This setting determines if a user can configure and initiate a job using the panels hard buttons. To change this setting: 1. Touch Num Pad Job Assist from the Configuration Menu. [setting's current value] appears on the touch-screen. 2. Touch or . The settings ...

3-8 Service Manual To adjust the flatbed edge erase setting, perform the following steps: 1. Touch FB Edge Erase from the Configuration Menu. [setting's current value] appears on the touch-screen. 2. Touch to increase the value or to decrease the value. 3. Touch Submit to save the change. 4. Touch B...

3-10 Service Manual Jobs on Disk Jobs On Disk allows you to delete buffered jobs saved on the disk. To delete jobs saved on the disk: 1. Touch Jobs On Disk from the Configuration Menu. 2. Touch to decrease the setting's value; touch to increase the setting's value. 3. Touch Back to cancel and return...

Diagnostic aids 3-11 The following graphic appears when the formatting process is selected: The panel provides many progress indicators during the two-stage process. • 1/2 indicates that the process is currently in the first stage. • 0% indicates the progress of the current stage of the process. • T...

Diagnostic aids 3-13 Wipe Disk This setting provides you with a tool for erasing the contents of a disk. Warning: Wipe Disk removes a disk's data in such a way that it cannot be recovered. To change this setting: 1. Touch Wipe Disk from the Configuration Menu. Note: If an advanced password has been ...

3-16 Service Manual Clear Custom Status No values exist for this operation. Pressing initiates this operation. Touch to select Clear Custom Status from the Configuration Menu. Note: Executing this operation erases any strings that have been defined by the user for the default or alternate custom mes...

Diagnostic aids 3-17 Diagnostics menu Entering Diagnostics menu 1. Turn off the printer. 2. Press and hold 3 and 6. 3. Turn on the printer. 4. Release the buttons after ten seconds. Available tests The tests display on the operator panel in the order shown: Note: Menus may vary depending on the feat...

Diagnostic aids 3-19 To set print registration: 1. Print the Quick Test page. a. Touch REGISTRATION from the Diagnostics Menu. b. Touch to select Quick Test. You may need to scroll to the next page. Retain this page to determine the changes you need to make to the margins settings. The diamonds in t...

3-20 Service Manual Print Tests This setting tests the printer’s ability to generate printed output from each of its installed input sources and to test the printer’s current print quality. Input sources The purpose of the diagnostic Print Tests is to verify that the printer can print on media from ...

Diagnostic aids 3-21 Hardware Tests Select the following Hardware Tests from this menu: • Panel Test • Button Test • DRAM Test • USB HS Test Mode Panel Test This test automatically toggles each pixel of the touchscreen through every contrast level beginning with the darkest and on to the brightest. ...

3-22 Service Manual DRAM Test The purpose of this test is to check the validity of DRAM memory, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: 1. Touch to select DRAM Test from the menu. The ...

Diagnostic aids 3-23 USB HS Test Mode 1. Select USB HS Test Mode from HARDWARE TESTS. 2. Press until the appears next to the Port to be tested, and then press . 3. Select the desired Test, and then press . To stop testing before completion, turn the printer off. Port Test Appears on the display Port...

3-24 Service Manual Duplex Tests Quick Test (duplex) This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page. You can run one duplexed page ( Single ), or continue printing duplexed pages ( Continuo...

Diagnostic aids 3-25 Top Margin (duplex) This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin. See “Registration (pri...

3-26 Service Manual 3. Touch Back or press Stop to exit the test. Duplex Feed 1 This test feeds a blank sheet of paper to the duplex paper stop position 1. This test can be run using any of the supported paper sizes. To run the Duplex Feed 1 Test: 1. Touch to select Duplex Feed 1 from DUPLEX TESTS. ...

Diagnostic aids 3-27 3. Select the sensor to test. Various sources have different combinations of sensors. See the table below: [ sensor selected ] =Open displays. • Empty—Input tray empty sensor • Low—Input tray paper low sensor • passThru—Input tray pass thru sensor 4. Once this message displays, ...

3-28 Service Manual Base Sensor Test This test is used to determine if the sensors located inside the printer are working correctly. To run the Base Sensor Test: 1. Select BASE SENSOR TEST from the DIAGNOSTICS menu. The following sensors are listed: • Input—Input sensor • Exit—Output (exit) sensor •...

Diagnostic aids 3-29 3. Once the test is complete, the power indicator turns on solid, and either the message Disk Test/Clean Test Passed or Disk Test/Clean Failed appears. If the message indicates failure, the disk is unusable. PRINTER SETUP The triangles pointing up or down indicate whether there ...

3-30 Service Manual The model name can only be viewed and cannot be changed. Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The configuration IDs are originally set at the factory whe...

Diagnostic aids 3-31 EP SETUP The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to display these additional menus. Note: If you make changes, touch Submit to make the change effective. EP Defaults This setting is used to restore each printer s...

Diagnostic aids 3-33 Print Log Additional diagnostic information is available when you print the event log from Diagnostics Menu rather than Configuration Menu. The Event Log printed from Diagnostics Menu includes: • Detailed printer information, including code versions • Time and date stamps • Page...

3-34 Service Manual Scanner Tests ASIC Test A pattern appears and ASIC Test Passed displays. If xxxxxx displays, the test was unsuccessful. Press Stop to return to the SCANNER TESTS menu. Feed Test To run the Scanner Feed test: 1. Touch to select Feed Test from the SCANNER TESTS menu. 2. The panel d...

Diagnostic aids 3-37 Exit Diagnostics Selecting EXIT DIAGNOSTICS exits the Diagnostics menu, and Resetting the Printer displays. The printer performs a POR, and the printer returns to normal mode.

3-38 Service Manual Printhead assembly electronic adjustment Note: Before aligning the printhead electronically, first align the printhead mechanically, if needed. See “Printhead assembly mechanical adjustment” on page 3-39 . 1. Enter the Diagnostics menu. See “Entering Diagnostics menu” on page 3-1...

Diagnostic aids 3-39 7. Print the Quick Test page again and check that the darkest line in the center graph is equal to zero. If it is, then check to see if the left, top, and bottom margins are detected. If it is not, then repeat step 5. Note: The alignment of the left margin positions the black pl...

3-40 Service Manual 7. If the grid lines of the right flap align below the corresponding lines on the left flap, then adjust the printhead clockwise relative to the printer, and recheck. (See the left side of the figure below.) If the grid lines of the left flap align below the corresponding lines o...

Diagnostic aids 3-41 SE Menu Note: This is not the Fax SE menu. To enter the Fax SE menu, press **411 from the Ready screen. Note: This menu should be used as directed by second-level support. Print SE Menus General Copyright - Displays copyright information. Optra Forms mode - On or off Code Revisi...

3-42 Service Manual Paper jams Avoiding jams Most paper jams can be avoided by correctly loading paper and specialty media in the printer. The following hints can help prevent paper jams: • Use only the recommended print media. • Do not overload the print media sources. Make sure the stack height do...

Diagnostic aids 3-43 Understanding jam numbers and locations The following illustration shows the areas of the MFP where jams occur. When paper jams occur, follow the instructions in this section. Jam area number Description 1 Opened front door 2 Paper output bin 3 Front door 4 Multi purpose feeder ...

3-44 Service Manual Jam messages and their locations 200 and 201 paper jams CAUTION: Hot surface. The inside of the printer may be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching it. 1. Pull the tray completely out. 2. Remove the paper jam.

Diagnostic aids 3-47 3. Remove the jam. 4. Close the rear door. 5. Close the front door. 6. Touch Continue .

3-54 Service Manual 7. Lock the ADF separator roll. 8. Close the ADF top cover. Clearing ADF jams under the flatbed cover. 1. Lift the flatbed cover, and remove the jammed media from the ADF. 2. Touch Continue .

Diagnostic aids 3-55 Clearing jams in the duplex ADF 1. Remove the ADF input tray. 2. Pull out the jammed media by pulling on the bottom sheet. 3. Reinstall the ADF input tray. 4. Touch Continue .

Repair information 4-1 4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instruction...

4-2 Removal procedures • Remove the toner cartridge and media tray before removing other printer parts. The toner cartridge should be protected from light while out of the printer. • We recommend disconnecting all external cables from the printer to prevent damage during service. • Unless otherwise ...

Repair information 4-3 ACM pick tire roller removal 1. Place the printer on its side. Note: Be careful to not mar the finish of the printer. 2. Open the duplex jam door just far enough to pull out the ACM pick tires. Warning: Open the duplex door only far enough to remove the ACM pick tires. If the ...

Repair information 4-5 Card reader removal 1. Remove the scanner front cover. See “Scanner front cover removal” on page 3-31 . 2. Remove the operator panel keypad assembly. See “Operator panel keypad removal” on page 4-62 3. Release the tabs on the rear of the operator panel display and tilt it upri...

4-6 Upper and lower card reader cover removal 1. Remove the scanner front cover. See “Scanner front cover removal” on page 3-31 . 2. Remove the card reader. See “Card reader removal” on page 4-5 . 3. Remove the four screws (A) fastening the upper and lower card reader covers. A

Repair information 4-7 Card reader cable removal 1. Remove the scanner front cover. See “Scanner front cover removal” on page 3-31 . 2. Remove the operator panel keypad assembly. See “Operator panel keypad removal” on page 4-62 3. Release the tabs on the rear of the operator panel display and tilt i...

4-8 Controller board removal Warning: • Always touch a ground before touching the board. • Handle the board carefully by the edges. • Never replace the operator panel and controller board without a successful POR in between. • Never replace the operator panel and the controller board at the same tim...

Repair information 4-9 4. Using a flatblade screwdriver, depress the kickstand release tab (B). 5. While depressing the tab, lift the scanner assembly until it is fully vertical. Warning: To avoid damage to the rear frame assemblies, hold the ADF while raising the flatbed to the upright position, th...

Repair information 4-11 Controller board shield 1. Remove the two screws (A) securing the controller shield bracket to the controller board cage. A

4-14 Controller board cage 1. Remove the controller board. See Go to “Controller board removal” on page 4-8 . 2. Remove the five screws (A) which secure the controller board cage to the tub assembly. 3. Tilt the front of the cage up and remove it from the MFP. Controller board fan 1. Remove the oper...

Repair information 4-15 Engine board removal 1. Remove the right side cover. See Go to “Right side cover removal” on page 4-77 . 2. Disconnect all the cables from the engine board. 3. Remove the three screws (A securing the engine board to the print engine frame. 4. Remove the engine board. CAUTION ...

4-16 Cover open sensor 1. Remove the right side cover. Go to “Right side cover removal” on page 4-77 . 2. Disconnect the cable from connector J11 on the controller board. 3. Use a #1 Phillips screwdriver to remove the screw (A) holding the sensor. 4. Remove the cover open sensor. A

Repair information 4-17 Door mount removal 1. Open the front cover. 2. Remove the lower front cover. See “Lower front cover removal” on page 4-35 . 3. Remove the left side cover. See “Left side cover removal” on page 4-33 . 4. Remove the right side cover. See “Right side cover removal” on page 4-77 ...

Repair information 4-19 Duplex removal 1. Remove the right side cover. See “Right side cover removal” on page 4-77 . 2. Remove the LVPS/HVPS. See “LVPS/HVPS removal” on page 4-37 . 3. Remove the three screws (A) from the shield. 4. Remove the four screws (B) from the duplex. A B

Repair information 4-21 Duplex/main motor gear drive interface removal 1. Remove the LVPS/HVPS. See “LVPS/HVPS removal” on page 4-37 . 2. Remove the duplex. See “Duplex removal” on page 4-19 . 3. Remove the main motor gear drive. See “Main motor gear drive removal” on page 4-40 . 4. Remove the e-cli...

4-24 Fan removal 1. Remove the right side cover. See “Right side cover removal” on page 4-77 . 2. Disconnect the cable (A) from the engine board, and remove the two screws (B) holding the fan to the right side frame. 3. Remove the fan. B A

Repair information 4-25 Front access door removal 1. Remove the front door access cover. See “Front door access cover removal” on page 4-34 . 2. Remove the left side cover. See “Left side cover removal” on page 4-33 . 3. Remove the upper front guide assembly. See “Upper front guide assembly removal”...

4-28 Fuser removal 1. Remove the rear exit guide. See “Rear exit guide assembly with sensor and reversing solenoid removal” on page 4-75 . 2. Remove the two screws (A). 3. Partially pull the fuser forward for better access.

Repair information 4-31 Scanner front cover removal 1. Use a flatblade screwdriver to pry the scanner front cover away from the side cover. Be careful to avoid marring the finish.

Repair information 4-33 Left side cover removal Note: • Leave the front door closed when removing the left side cover. • Make sure that the fuser cables are out of the way when removing the left side cover. 1. Remove the scanner front cover. See “Scanner front cover removal” on page 4-31 . 2. Move t...

4-34 7. Depress the two tabs (C) on the underside of the MFP. 8. Lift the left cover up and pull the bottom of the cover away from the MFP. Note: You will need to pry the MPF cover door forward slightly to provide clearance to the left cover when you pull the cover away from the machine. Front door ...

Repair information 4-35 Lower front cover removal 1. Open the lower front cover. 2. Disconnect the MPF pins (A) from the right and left sides of the lower front cover. 3. Flex the lower front cover, and disconnect it first from its right hinge and then from its left hinge. Note: An alternative to st...

Repair information 4-37 LVPS/HVPS removal 1. Remove the rear cover. See “Rear door and lower rear cover removal” on page 4-74 . 2. Remove the left side cover. See “Left side cover removal” on page 4-33 . 3. Place the printer on its top with the rear facing you. Note: Be careful to not mar the finish...

4-40 Main motor gear drive removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33 . 2. Disconnect the fuser link (A) from the front access door. 3. Place the printer on its right side. Note: Be careful to not mar the finish of the printer. 4. Remove the four screws (B) fro...

4-42 Manual feed clutch removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33 . 2. Open the front access door, and disconnect the fuser link (A). 3. Place the printer on its right side. Note: Be careful to not mar the finish of the printer. 4. Remove the four screws (B) f...

4-44 Manual feed solenoid removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33 . 2. Remove the duplex. See “Duplex removal” on page 4-19 . 3. Open the front access door, and place the printer on its right side. Note: Be careful to not mar the finish of the printer. 4. Re...

Repair information 4-47 Media ACM ASM feeder removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33 . 2. Remove the LVPS/HVPS. See “LVPS/HVPS removal” on page 4-37 . 3. Remove the duplex. See “Duplex removal” on page 4-19 . 4. Remove the main motor gear drive. See “Main mo...

4-50 Media feed clutch with cable removal 1. Remove the main motor gear drive. See “Main motor gear drive removal” on page 4-40 . 2. Remove the duplex. See “Duplex removal” on page 4-19 . 3. Disconnect the media feed clutch cable (A) from J34 on the engine board. 4. Un route the cable from the botto...

4-52 Media manual input sensor 1. Remove the right side cover. See “Right side cover removal” on page 4-77 . 2. Remove scanner assembly. 3. Place the machine on its side. Note: Be careful to not mar the finish of the printer. 4. Disconnect the sensor cable (A) from J23 (MPFS) on the engine board. 5....

Repair information 4-55 Multipurpose feeder removal 1. Open the front access door. 2. Remove the four screws (A) from the upper front guide. 3. Remove the upper front guide. 4. Remove the two screws (B). A B

4-58 Multipurpose feeder (MPF) feed clutch removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33 . 2. Remove the duplex. See “Duplex removal” on page 4-19 . 3. Disconnect the cable (A) from J24 on the engine board. 4. Place the printer on its right side. Note: Be careful ...

Repair information 4-61 Nameplate cover removal 1. Open the front access door. 2. Remove the three screws (A). 3. Remove the nameplate. A

4-62 Operator panel keypad removal 1. Lift the scanner assembly to the up position. 2. Release the two tabs (A) securing the keypad to the keypad to the tub assembly. 3. Disconnect the UICC cable (B) from the operator panel PCB assembly. 4. Disconnect the two ribbon cables (C) from the operator pane...

Repair information 4-63 Operator panel display removal 1. Remove the operator panel keypad. 2. Press the tab on the left side of the operator panel display and raise the operator panel display to the up position. 3. Press the tabs (A) which fasten the operator panel display to the display rotation s...

4-64 Display bezel 1. Remove the operator panel display. See “Operator panel display removal” on page 4-63 . 2. Depress the two tabs (A) securing the display bezel to the operator panel display. 3. Pull the bezel away from the display. A

Repair information 4-65 UICC cable removal 1. Lift the scanner assembly to the up position. 2. Disconnect the UICC cable from the controller board. 3. Feed the cable through the hole in the front of the controller card cage. 4. Release the two tabs (A) securing the keypad to the keypad to the tub as...

4-66 USB cable mount bracket removal 1. Remove the operator panel keypad. 2. Open the USB cable clamp and remove the USB cable. 3. Remove the screw (A) securing the USB cable mount bracket to the tub assembly. Operator panel support removal 1. Remove the operator panel keypad. 2. Remove the three sc...

Repair information 4-67 Display rotation support removal 1. Remove the operator panel display. See “Operator panel display removal” on page 4-63 . 2. Remove the three screws (A) securing the display rotation support to the tub assembly. Note: The same steps are performed for both supports. A

4-68 Left rear frame assembly removal 1. Remove the flatbed assembly. See “Flatbed removal” on page 4-86 . 2. Remove the three screws (A) from the left rear frame assembly. 3. Carefully lift the left rear frame assembly off of the print engine frame. A A A A

Repair information 4-69 Right rear frame assembly removal 1. Remove the flatbed assembly. See “Flatbed removal” on page 4-86 . 2. Remove the three screws (A) from the right rear frame assembly. 3. Carefully lift the right rear frame assembly off of the print engine frame. B A B A B A

4-70 Tub assembly removal 1. Remove the flatbed assembly. See “Flatbed removal” on page 4-86 . 2. Disconnect the remaining cables from the controller board. 3. Thread the cables through the tub assembly and top cover. 4. Remove the controller board cage. See “Controller board cage” on page 4-14 . 5....

Repair information 4-71 Paper input and duplex sensor assembly removal 1. Remove the right side cover. See “Right side cover removal” on page 4-77 . 2. Remove the duplex. See “Duplex removal” on page 4-19 . 3. Remove the two screws (A) from the sensors. 4. Disconnect the sensor cable (B) from the co...

4-72 Printhead removal 1. Remove the top cover. See “Top cover assembly removal” on page 4-80 . 2. Remove the right side cover. See “Right side cover removal” on page 4-77 . 3. Disconnect the two cables (A), and unroute them back through the frame toward the printhead. 4. Remove the three screws (B)...

Repair information 4-73 Mid rear cover removal 1. Remove the two metal screws (A). 2. Pull the upper rear cover back. 3. Carefully disengage that snaps and remove the cover. A

4-74 Rear door and lower rear cover removal 1. Remove the mid rear cover. See “Mid rear cover removal” on page 4-73 . 2. Open the rear door. 3. Pull the rear door up at an angle, disconnect the door from the notch (A), and remove. 4. Remove the two screws (B) from the top of the rear cover. 5. Tilt ...

Repair information 4-77 Right side cover removal Note: Leave the front cover closed when removing the right side cover assembly. 1. Remove the scanner front cover. See “Scanner front cover removal” on page 4-31 . 2. Lift and lock the scanner assembly in the up position. See “Lifting the Scanner to t...

Repair information 4-79 Toner level sensor removal 1. Open the front access door. 2. Remove the right side cover. See “Right side cover removal” on page 4-77 . 3. Disconnect the toner level sensor cable (A) from the engine board. 4. Squeeze the lower tabs (B) of the toner level sensor, and push it f...

4-80 Top cover assembly removal 1. Remove the scanner assembly. See “Scanner assembly removal” on page 4-88 . 2. Lift the top cover, and remove. Note: • Be sure to lift the top cover assembly from the front to remove. • During reinstallation, be sure the exit guide and the paper bin align correctly....

Repair information 4-81 Transfer roll removal Note: A flashlight may be required to remove the transfer roll. 1. Open the front access door. 2. At the right side of the transfer roll, squeeze the holder arms (A) with the left hand while lifting. Stop when the holder is unlatched. 3. At the left side...

4-82 Upper front guide assembly removal 1. Open the front access door. 2. Remove the four screws (A) from the upper front guide. 3. Remove the upper front guide. A

Repair information 4-85 Imaging component removals ADF unit removal 1. Remove the ADF rear cover by releasing the three tabs (A) which fasten the ADF rear cover to the ADF unit. 2. Disconnect the ADF cable (B) and two sensor connections (C) on the relay card above the ADF relay cable. 3. Lift the AD...

4-86 Flatbed removal 1. Remove the left side cover. See “Left side cover removal” on page 4-33 . 2. Remove the left scanner cover. See “Left scanner cover removal” on page 4-100 . 3. Remove the right scanner cover. See “Right scanner cover removal” on page 4-101 . 4. Remove the right side cover. See...

4-88 13. Remove the kickstand (B). 14. Remove the two flatbed supports (C). These will be used on the new flatbed. 15. Remove the controller shield (D). This will be used on the new flatbed. Scanner assembly removal 1. Remove the left scanner cover. See “Left scanner cover removal” on page 4-100 . 2...

Repair information 4-95 ADF separator pad 1. Remove the ADF separator roll. See “ADF separator roll assembly” on page 4-96 . 2. Pinch the two tabs on each side of the pad inward. 3. Tilt the pad up, and lift it out of the ADF assembly.

4-96 ADF separator roll assembly 1. Lift the locking lever (A). 2. Slightly lift the separator roll assembly, and pull it out of the mount (B) on the opposite side. A B

Repair information 4-97 Kickstand removal 1. Lift the flatbed assembly to the up position. 2. Release the kickstand from the left rear frame assembly by depressing the tab holding the kickstand in place. 3. Remove the e-clip (A) securing the kickstand rod to the flatbed. 4. Slide the rod out and rem...

4-98 Output bin LED and lens removal 1. Disconnect the output LED cable from the controller board. 2. Remove the controller board cage. See “Controller board cage” on page 4-14 . 3. Press the tab (A) securing the lens to the tub assembly. 4. Pull down on the lens and LED and remove it from the tub. ...

Repair information 4-99 ADF cable removal 1. Remove the left scanner cover. See “Left scanner cover removal” on page 4-100 . 2. Remove the left cover. See “Left side cover removal” on page 4-33 . 3. Remove the controller board shield. See “Controller board shield” on page 4-11 . 4. Lift the flatbed ...

4-100 9. Remove the ADF cable from the MFP. Left scanner cover removal 1. Lift the ADF to the up position. 2. Remove the two screws (A) securing the left scanner cover to the flatbed unit. 3. Lift and carefully pull the left scanner cover up and away from the rear of the flatbed. A

Repair information 4-101 Right scanner cover removal 1. Lift the ADF to the up position. 2. Remove the two screws (A) securing the right scanner cover to the flatbed unit. 3. Lift and carefully pull the right scanner cover up and away from the rear of the flatbed. X A

4-102 Option board installs and removals Note: This information is also available in the X 46x series user guide. Lifting the Scanner to the up position 1. Turn the two rear frame assembly locks counter-clockwise to the unlock position. 2. Lift the scanner assembly to the up position. The kickstand ...

Repair information 4-103 Installing an Internal Solutions Port (ISP) 1. Access the controller board. See “Lifting the Scanner to the up position” on page 4-102 . 2. Unpack the ISP and tee. Note: Avoid touching components on the card. 3. Locate the standoff location on the controller board. Note: If ...

4-106 Printer hard disk removal 1. Unplug the printer hard disk interface cable from the system board. 2. Remove the screws holding the printer hard disk in place.

Repair information 4-107 3. Remove the printer hard disk by pulling it upwards from the standoffs. 4. Remove the thumbscrews that attach the printer hard disk mounting bracket to the printer hard disk if the drive is going to be installed on top of an ISP. Printer hard disk installation on an ISP 1....

Repair information 4-109 Printer hard disk installation directly on the controller board Note: Perform steps 1, 2, and 3 from above. before doing the rest of the installation. 1. Align the printer hard disk standoffs with the holes on the system board. 2. Press the hard disk down until it locks into...

4-110 4. Connect the hard disk interface cable to the connector on the controller board. Fax card installation 1. Access the controller board. 2. Unpack the fax card, 3. Remove the fax card cover on the controller board cage. 1 2

Locations and connections 5-1 5. Locations and connections Locations Front view Callout number Item name 1 Front door release button 2 E-Task display / Operator panel 3 ADF unit 4 Output bin / cave 5 Output bin extension 6 Standard input tray 7 MFP input tray 8 Front cover access 3 4 5 6 7 8 1 2

5-2 Service Manual Rear view Callout number Item name 1 Scanner locks 2 Kensington lock 3 Ethernet port 4 Host USB port 5 Fax / 6 Fax / 7 Rear door 8 Power switch 9 Power 10 Rear USB 11 ISP / Options cover

Locations and connections 5-3 Print engine paperpath A Paper path A – B 125.3 B Manual feed sensor B – C 9.0 C Upper end feed rolls C – D 59.8 D Input sensor D – E 44.9 E Transfer roll E – F 112.7 F Fuser F – G 21.4 G Fuser exit rolls G – H 114.8 H Fuser exit sensor H – I 7.5 I Exit rolls I – J 17.0...

5-4 Service Manual Main boards J6 J6 J11 1 1 1 J26 J27 1 1 J16 1 J3 1 J3 1 J28 J13 1 J12 J17 1 1 J5 1 J4 1 J1 J8 1 J25 1 J7 1 J2 1 J35 1 J37 1 J34 J33 1 J10 J99 J30 Controller board

Locations and connections 5-5 1 1 J500 J501 J502 J503 1 1 1 J4 1 J13 J504 1 J23 1 J24 J50 1 J25 J34 J27 1 1 1 J28 1 J10 1 J14 J12 1 1 J35 1 J17 1 J36 1 1 Engine board

5-6 Service Manual Note: The connections listed below are located on the controller board or the engine board. The comments column lists which board the connection appears on. Note: See the wiring diagram at back of book. These values were measured with all connections made (plugged) or with only on...

Preventive maintenance 6-1 6. Preventive maintenance This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help prevent problems and maintain optimum performance. Safety inspection guide The purpose of this inspection guide is to aid you in identifying...

Parts Catalog 7-1 7. Parts Catalog How to use this parts catalog The following legend is used in the parts catalog: • Asm-index : identifies the assembly and the item in the diagram. For example, 3-1 indicates assembly 3 and the item number 1. • Part number : identifies the unique number that identi...

7-6 Service Manual Assembly 3: Tray assemblies 3 2 1 5 4

Parts Catalog 7-7 Assembly 3: Tray assemblies Asm- Index Part number Units/mach Units/ FRU Description 3-1 40X5398 1 1 Optional 250-sheet tray (new asm) 1 40X5399 1 1 Optional 550-sheet tray (new asm) 2 40X5394 1 1 250-sheet (Tray 2) assembly (new asm) 2 40X5395 1 1 550-sheet (Tray 2) assembly (new ...

7-8 Service Manual Assembly 4: Electronics 11 12 7 13 6 14 8 1 2 3 4 5 9 10 17 20 18 19 22 21 16 15

Parts Catalog 7-9 Assembly 4: Electronics Asm- Index Part number Units/mach Units/ FRU Description 4-1 40X5829 1 1 Controller board 2 40X5816 1 1 LSU hsync extension cable 3 40X5832 1 2 Stairway cable 4 40X5833 1 1 Controller board cable 5 40X5344 1 1 Fuser assembly, 115 V 5 40X5345 1 1 Fuser assemb...

7-10 Service Manual Assembly 5: Frame 7 1 2 5 6 7 12 8 See instruction sheet in the FRU. 9 10 11 3 4 3

Parts Catalog 7-13 Assembly 7: Power cords Asm- Index Part number Units/mach Units/ FRU Description NS 40X0297 1 1 Power cord, 1.8M (straight)—USA, Canada NS 40X0278 1 1 Power cord, 6 foot (straight)—Europe and others NS 40X0288 1 1 Power cord, 8 foot (straight)—Argentina NS 40X0286 1 1 Power cord, ...

Index I-1 Index Numerics 840.xx service check 2-55 A abbreviations 1-14 acronyms 1-14 ADF cover open service check 2-59 ADF duplex service check 2-62 ADF feed errors service check 2-61 ADF paper jam service check 2-60 ADF separator pad removal 4-95 ADF separator roll removal 4-96 ADF streak service ...

Part number index I-5 Part number index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12 40X0270 Power cord, 1.77M (straight)—Japan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ...