4060 Xxx Service Manual (P/N 12G9221) Lexmark T630

User Manual: Service Manual La Biblioteca de los 8 bits

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Lexmark™ T63x
(including Lexmark T630, Lexmark T632, Lexmark T634)

4060-xxx
(including 4060-000, 4060-010, 4060-200,
4060-210, 4060-400, 4060-410)

• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index

Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

4060-xxx

Edition: June 2003
The following paragraph does not apply to any country where such provisions are inconsistent with local law:
LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,
EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or
implied warranties in certain transactions; therefore, this statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the
information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the
programs described may be made at any time.
Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road,
Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any
of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase
additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of
purchase.
Lexmark, Lexmark with diamond design, MarkNet, MarkVision, and Prebate are trademarks of Lexmark International, Inc.,
registered in the United States and/or other countries.
ImageQuick, Optra Forms, PrintCryption, and StapleSmart are trademarks of Lexmark International, Inc.
LEXFAX is a service mark of Lexmark International, Inc.
Other trademarks are the property of their respective owners.

© 2003 Lexmark International, Inc.
All rights reserved.
UNITED STATES GOVERNMENT RIGHTS
This software and any accompanying documentation provided under this agreement are commercial computer software
and documentation developed exclusively at private expense.
P/N 12G9328

4060-xxx

Table of contents
Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Print speed and performance print speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time to first print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3
1-3
1-4
1-4

Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power and electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acoustics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5
1-5
1-6
1-6
1-6
1-7
1-7

Media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Print area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Media guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Envelopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Transparencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Messages and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Sub error codes for 9xx and 2xx error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Base printer sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Base printer (fuser) sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Duplex option sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Envelope feeder sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
User status displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
User status messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
User line 2 link messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Check device connection messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Table of contents

iii

4060-xxx

Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Base printer symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
High-capacity feeder (2000-sheet) symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Paper tray symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Duplex option symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Envelope feeder symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Output expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
StapleSmart finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
5-Bin mailbox service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
900 Error Code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
950 Error Code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Charge roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Cover closed switch/cable service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Duplex option service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Envelope feeder service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Fuser service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Cold fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Hot fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Fuser solenoid service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
High-capacity feeder input tray service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
High-capacity output stacker service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
Input sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Input tray(s) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
Internal tray card/paper size sensing service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
Main drive service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Main fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Operator panel buttons service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Operator panel display service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Options service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Flash Memory Option(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
DRAM Memory Option(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Hard Disk Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Output bin sensor standard tray service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Output expander service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
Paper feed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Parallel port service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
Smart contact assembly service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
StapleSmart finisher service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
Toner sensor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94

iv Service Manual

4060-xxx

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entering Diagnostic Mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exiting Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1
3-1
3-1
3-1

Device tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2
3-2
3-2
3-3
3-3

Duplex tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duplex Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duplex Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4
3-4
3-4
3-5
3-5
3-6

Error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Viewing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing the error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6
3-6
3-7
3-8

Hardware tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SDRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8
3-8
3-8
3-9
3-9
3-9

Input tray tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Input Tray Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Input Tray Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Output Bin Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Bin Test–Standard Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Bin Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feed to All Bins Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Bin Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11
3-11
3-11
3-12
3-12

Finisher Tests for StapleSmart Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finisher Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finisher Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Staple Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover and Door Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pass and Media Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bin Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14
3-14
3-14
3-15
3-15
3-15
3-15

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Print registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Printer setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Setting the page count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Viewing the permanent page count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Table of contents

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4060-xxx

Maintenance page count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Setting configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Restore EP Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Print tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Print quality test pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Printing menu settings page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Autocompensator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Autoconnect system, paper tray options, envelope feeder–electrical . . . . . . . . . . . . . . . 3-21
Autoconnect cabling and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Duplex Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Option microcode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Paper feed jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Paper jams–base printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Paper jams–options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Error Message 23x Paper Jam - Check Duplex Option . . . . . . . . . . . . . . . . . . . . . . . 3-24
Error Message 24x (x=tray 1 through 5) Paper Jam Check Tray x . . . . . . . . . . . . . . 3-25
Error Message 250 Paper Jam - Check MP Feeder . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Error Message 260 Paper Jam - Check Envelope Feeder . . . . . . . . . . . . . . . . . . . . 3-25
Error Message 27x Paper Jam - Check Bin x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Error Message 28x Paper Jam (x=StapleSmart finisher) . . . . . . . . . . . . . . . . . . . . . . 3-25
Error Message 282 - Check Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Error Message 283 - Check Stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Adjustment procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Duplex motor drive belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fuser solenoid adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Printhead assembly adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Paper alignment assembly adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Screw identification table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Covers removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Left door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Upper front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Laser cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Bevel gear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Communications board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Cover closed switch/cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Developer drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Frames removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
EP frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Left side frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Right side frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Fuser assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

vi Service Manual

4060-xxx

Fuser cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser exit sensor or fuser narrow media sensor removal . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser lamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser transfer plate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High voltage power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner paper deflector assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inner shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated tray autocompensator assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated tray autocompensator pick roll assembly removal . . . . . . . . . . . . . . . . . . . . . .
Interconnect board assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal tray card (ITC)/Paper size sensing board removal . . . . . . . . . . . . . . . . . . . . . . . .
Low voltage power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multipurpose tray/lower deflector assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator panel assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator panel bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator panel cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional 250 or 500-sheet paper tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . .
Paper tray autocompensator assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper tray frame assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper tray board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper tray paper out sensor flag removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper size spring comb removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outer shield removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper alignment assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper bin full sensor flag assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pick roll removal (MPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redrive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Smart contact assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toner sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper front cover hinge assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper paper deflector assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-25
4-28
4-28
4-30
4-31
4-33
4-34
4-34
4-35
4-38
4-40
4-41
4-42
4-44
4-46
4-47
4-48
4-49
4-50
4-51
4-51
4-51
4-51
4-51
4-51
4-52
4-52
4-54
4-55
4-56
4-57
4-58
4-58
4-61
4-61
4-62
4-63

Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Autoconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Envelope feeder board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-capacity output stacker board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High voltage power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnect board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low voltage power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output expander control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
StapleSmart finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1
5-2
5-2
5-3
5-4
5-5
5-6
5-7
5-8

Table of contents

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System board–non-network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
System board–network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Assembly 2: Frame 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly 3: Frame 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Assembly 4: Printhead 1 (000/010) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Assembly 5: Printhead 2 (200/210) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Assembly 6: Printhead 3 (400/410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Assembly 7: Paper feed–autocompensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Assembly 8: Paper feed–multipurpose feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Assembly 9: Paper feed–alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Assembly 10: Integrated paper tray–250-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Assembly 11: Integrated paper tray–500-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Assembly 12: Drives–Main drive and developer drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Assembly 13: Hot roll fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Assembly 14: Transfer/charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Assembly 15: Electronics–power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Assembly 16: Electronics–card assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Assembly 17: Electronics–shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Assembly 18: Cabling diagrams 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Assembly 19: Cabling diagrams 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Assembly 20: Cabling diagrams 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Assembly 21: 250-sheet paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Assembly 22: 500-sheet paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Assembly 23: Duplex option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Assembly 24: Envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Assembly 25: Output expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Assembly 26: High-capacity output expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Assembly 27: 5-bin mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Assembly 28: High-capacity feeder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Assembly 29: High-capacity feeder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Assembly 30: High-capacity feeder 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Assembly 31: High-capacity feeder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Assembly 32: High-capacity feeder 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Assembly 33: Kiosk–vertical paper adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Assembly 34: Kiosk–horizontal paper adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Assembly 35: StapleSmart finisher I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
Assembly 36: StapleSmart finisher 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Assembly 37: StapleSmart finisher 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Assembly 38: StapleSmart finisher 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
Assembly 39: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
Assembly 40: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1
Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-7

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Laser notices
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for
Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the
requirements of IEC 60825-1.
Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb
(3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of
770-795 nanometers. The laser system and printer are designed so there is never any human
access to laser radiation above a Class I level during normal operation, user maintenance, or
prescribed service condition.

Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In
anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC
(International Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.
Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser
der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen
der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß
im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch
den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls
erreicht.

Avis relatif à l’utilisation de laser
Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J
concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux
normes IEC 60825-1 relatives aux produits laser de Classe I.
Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette
imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance
nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795
nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions
normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements
laser supérieurs à des rayonnements de Classe I .

Laser notices

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Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR
Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di
classe 1 conforme ai requisiti della norma CEI 60825-1.
I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un
laser di classe IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda
compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale
che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di
servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.

Avisos sobre el láser
Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de
Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de
Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma
IEC 60825-1 para productos láser de Clase I (1).
Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un
láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una
longitud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de
forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel
de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra
situación de servicio técnico.

Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação
DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada
como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1.
Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém
um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts
,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a
impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso
humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção
feita pelo utilizador ou condições de assistência prescritas.

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Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de
Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 60825-1.
Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een
laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een
golflengte van 770-795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal
gebruik, bij onderhoud of reparatie conform de voorschriften, nooit blootstelling mogelijk is aan
laserstraling boven een niveau zoals voorgeschreven is voor klasse 1.

Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for
en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske
servicebetingelser.

Huomautus laserlaitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.
Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb
(3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä
voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai
muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso
säteeseen.
VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad.
strålen.

Betrakta ej

Laser notices

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Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för
laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I
enligt kraven i IEC 60825-1.
Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som
består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795
nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person
utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av
användaren eller annan föreskriven serviceåtgärd.

Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1)
laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i
IEC 60825-1.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb
(3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for
laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller
foreskrevne serviceoperasjoner.

Avís sobre el Làser
Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21
CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un
producte làser de classe I que compleix els requisits d’IEC 60825-1.
Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de
classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud
d’ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que
mai hi hagi exposició a la radiació làser per sobre d’un nivell de classe I durant una operació normal,
durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions
prescrites.

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Japanese Laser Notice

Laser notices

xiii

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Korean Laser Notice

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Safety information
• The safety of this product is based on testing and approvals of the original design and specific
•
•
•

components. The manufacturer is not responsible for safety in the event of use of unauthorized
replacement parts.
The maintenance information for this product has been prepared for use by a professional
service person and is not intended to be used by others.
There may be an increased risk of electric shock and personal injury during disassembly and
servicing of this product. Professional service personnel should understand this and take
necessary precautions.
CAUTION: When you see this symbol, there is a danger from hazardous voltage in the
area of the product where you are working. Unplug the product before you begin, or use
caution if the product must receive power in order to perform the task.

Consignes de sécurité
• La sécurité de ce produit repose sur des tests et des

•
•
•

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant
n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de
rechange non agréées.
Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel
de maintenance qualifié.
Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le
personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.
ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie
du produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou
faites preuve de vigilance si l'exécution de la tâche exige que le produit reste sous
tension.

Norme di sicurezza
• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei
•
•
•

componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione
non autorizzata delle parti.
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al
personale di assistenza autorizzato.
Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza
autorizzato deve, quindi, adottare le precauzioni necessarie.
ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del
prodotto. Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve
essere alimentato per eseguire l'intervento.

Safety information

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Sicherheitshinweise
• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells
•
•
•

und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller
keine Verantwortung oder Haftung für die Sicherheit übernommen.
Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch
einen Wartungsfachmann bestimmt.
Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches
Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal
sollte entsprechende Vorsichtsmaßnahmen treffen.
ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in
diesem Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät
den Netzstecker des Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt
für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

Pautas de Seguridad
• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y
•
•
•

componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de
piezas de repuesto no autorizadas.
La información sobre el mantenimiento de este producto está dirigida exclusivamente al
personal cualificado de mantenimiento.
Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la
reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar
las precauciones necesarias.
PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está
trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si,
para trabajar con él, debe conectarlo.

Informações de Segurança
• A segurança deste produto baseia-se em testes e aprovações do modelo original e de
•
•
•

xvi

componentes específicos. O fabricante não é responsável pela segunrança, no caso de uso de
peças de substituição não autorizadas.
As informações de segurança relativas a este produto destinam-se a profissionais destes
serviços e não devem ser utilizadas por outras pessoas.
Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste
produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.
CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial
tensão perigosa na zona do produto em que está a trabalhar. Antes de começar,
desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de
estar ligado à corrente eléctrica para realizar a tarefa necessária.

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Informació de Seguretat
• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els

•
•
•

components específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.
La informació pel manteniment d’aquest producte està orientada exclusivament a professionals
i no està destinada
a ningú que no ho sigui.
El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de
servei d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre
les mesures convenients.
PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual
esteu treballant és perillós. Abans de començar, desendolleu l'equip o extremeu les
precaucions si, per treballar amb l'equip, l'heu de connectar.

Safety information

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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
2.
3.
4.
5.
6.
7.

approach used to repair it. Special tools and test equipment are listed in this chapter, as well as
general environmental and safety instructions.
Diagnostic information contains an error indicator table, symptom tables, and service checks
used to isolate failing field replaceable units (FRUs).
Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer
problems.
Repair information provides instructions for making printer adjustments and removing and
installing FRUs.
Connector locations uses illustrations to identify the connector locations and test points on the
printer.
Preventive maintenance contains the lubrication specifications and recommendations to
prevent problems.
Parts catalog contains illustrations and part numbers for individual FRUs.

Definitions
Note: A note provides additional information.
Warning: A warning identifies something that might damage the product hardware or software.
CAUTION: A caution identifies something that might cause a servicer harm.
CAUTION: When you see this symbol, there is a danger from hazardous voltage in the
area of the product where you are working. Unplug the product before you begin, or use
caution if the product must receive power in order to perform the task.

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1. General information
The Lexmark™ T63x laser printers are letter quality page printers designed to attach to
IBM-compatible personal computers and to most computer networks.
The Lexmark T63x laser printers are available in the following models:
Model name

Configuration

Machine type

Lexmark T630

Non-network

4060-000

Lexmark T630n

Network

4060-010

Lexmark T632

Non-network

4060-200

Lexmark T632n

Network

4060-210

Lexmark T634

Non-network

4060-400

Lexmark T634n

Network

4060-410

Maintenance approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part.
Use the service error codes, user status messages, user error messages, service checks, and
diagnostic aids to determine the printer problem and repair the failure. After you complete the repair,
perform tests as needed to verify the repair.

General information

1-1

4060-xxx

Options
The following options are available. Some options are not available in every country. Contact your
point of purchase for options available in your country.

•
•
•
•

•

•

•

Memory options of 8MB, 16MB, 32MB, 64MB and 128MB SDRAM
Flash memory options of 16MB and 32MB
Hard disk–20GB+ with adapter
Integrated network options
— Token-ring
— Ethernet
— External serial adapter
— IR adapter
— IPDS card assembly and SCS/TNe
— ImageQuick™ card assembly
— Bar code card assembly
— Parallel interface card
— MarkNet™ Print Servers
— Lexmark PrintCryption™ card
Media handling operations
— 250- and 500-sheet paper trays of A4, letter, A5, B5, Executive, folio, statement, and legal
size
— 250-sheet universally adjustable tray
— 250- and 500-sheet paper drawers
— 400-sheet universally adjustable tray
— 2000-sheet high-capacity feeder
— Envelope feeder
— Duplex option–250-sheet (For Lexmark T630 and Lexmark T630n)
— Duplex option–500-sheet (For Lexmark T632, Lexmark T632n, Lexmark T634, and
Lexmark T634n)
— Output expander
— High-capacity output stacker
— StapleSmart™ Finisher
— 5-bin Mailbox
— Vertical Kiosk Presenter
— Horizontal Kiosk Presenter
Application solutions
— Lexmark Document Solutions
— Optra Forms™, including a Forms Hard Disk–20+GB with adapter
DBCS font cards
— Simplified Chinese
— Traditional Chinese
— Japanese

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Print speed and performance print speed
Performance
Performance speed depends on:

•
•
•
•
•
•
•

Interface to the host (USB, serial, parallel, network)
Host system and application
Page complexity and content
Printer options installed or selected
Available printer memory
Media size and type
Resolution

The following table specifies throughput based on resolution and media size.
Lexmark T630,
Lexmark T630n
300, 600,
1200
image
quality

1200 dpi

Lexmark T632,
Lexmark T632n
300, 600,
1200
image
quality

1200 dpi

Lexmark T634,
Lexmark T634n
300, 600,
1200
image
quality

1200 dpi

Simplex printing on full-size media (pages per minute)
Letter
8.5 in. x 11 in.

35.1

18.0

40.1

21.5

45

A4
8.3 in. x 11.7 in.

33.2

17.1

38.0

20.4

43

Legal
8.5 in. x 14 in.

28.4

14.6

32.8

17.4

Duplex printing on letter-size media (sides per minute)
Letter
8.5 in. x 11 in.

30.6

16.9

33.2

19.2

A4
3.4 in. x 11.7 in.

29.2

16.1

31.6

18.3

Legal
8.5 in. x 14 in.

22.6

14.4

27.8

15.8

General information

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4060-xxx

Time to first print
Lexmark T630,
Lexmark T630n
Time from standby mode
Time from Power Saver mode

Lexmark T632,
Lexmark T632n

<8.5 sec.

<10 sec.

42 sec.

42 sec.

Lexmark T634,
Lexmark T634n

All first copy times are measured for 600 dpi simplex printing on letter size paper. The test job consists of the
character “A” followed by a form-feed (single page job). The first copy time is defined as the elapsed time
from pressing Enter on the PC keyboard to the page exiting to the output bin. All tests pick paper from the
indicated tray and the page exits into the primary output bin.

Memory configuration
Memory

Lexmark T630,
Lexmark T630n

Lexmark T632,
Lexmark T632n

Lexmark T634,
Lexmark T634n

Standard DRAM

32/64MB

64/64MB

64/80MB

Maximum

288/320MB

320/320MB

320/336MB

Depending upon the options and features used, additional memory may be required to optimize
performance.

Available memory options
Optional 8MB, 16MB, 32MB, 64MB, and 128MB SDRAM DIMMs are available from Lexmark. The
memory options are 168-pin synchronous DRAM DIMMs.
Flash memory options include 16MB and 32MB.

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Printer specifications
Dimensions
Description

Width

Depth

Height

Weight

Lexmark T630 (base printer)

16.6 in.
(421 mm)

19.6 in.
(498 mm)

13.6 in.
(345 mm)

38 lb
(17 kg)

Lexmark T632 (base printer)

17.2 in.
(436 mm)

20.2 in.
(513 mm)

16 in.
(406 mm)

41.5 lb
(19 kg)

Lexmark T634 (base printer)

17.2 in.
(436 mm)

20.2 in.
(513 mm)

16 in.
(406 mm)

41.5 lb
(19 kg)

2,000-Sheet drawer

15.6 in.
(398 mm)

19.5 in.
(495 mm)

11.8 in.
(300 mm)

28 lb
(12.7 kg)

Output Expander

15.6 in.
(398 mm)

14.9 in.
(374 mm)

6.8 in.
(173.2 mm)

7 lb
(3.2 kg)

500-Sheet drawer

15.6 in.
(398 mm)

20.5 in.
(520 mm)

5.3 in.
(134 mm)

7 lb
(3.2 kg)

250-Sheet drawer

15.6 in.
(398 mm)

19.5 in.
(495 mm)

3.5 in.
(90 mm)

6 lb
(2.7 kg)

5-Bin Mailbox

15.7 in.
(399 mm)

12.2 in.
(310 mm)

13.1 in.
(332 mm)

8.2 lb
(3.7 kg)

High-capacity output stacker

15.7 in.
(399 mm)

18 in.
(457 mm)

11.4 in.
(290 mm)

10 lb
(4.5 kg)

StapleSmart finisher

17.6 in.
(447.7 mm)

19.5 in.
(495.3 mm)

9.0 in.
(228.6 mm)

13 lb
(5.9 kg)

Printer

Options

Envelope option (closed position)

*

7.72 in.
(196 mm)

*

4 lb
(1.8 kg)

Envelope option (support fully
extended)

*

12.28 in.
(312 mm)

*

4 lb
(1.8 kg)

Printer cabinet

30.4 in.
(772 mm)

23.2 in.
(594 mm)

31.8 in.
(808 mm)

76 lb
(34.5 kg)

Printer cabinet stand

34.8 in.
(883 mm)

23.2 in.
(594 mm)

31.8 in.
(808 mm)

83 lb
(37.6 kg)

* Envelope option fits within height and width of printer.

General information

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4060-xxx

Operating clearances
Printer side

Measurement

Left and right side

12 in. (304.8 mm)

Front

20 in. (508 mm)

Rear

12 in. (304.8 mm)

Top*

54 in. (1,371.6 mm)

* Allow clearance above the printer front door clearance and for adding
options, such as additional input drawers, output expander, high-capacity
output stacker, or StapleSmart finisher.

Power and electrical specifications
Average nominal power requirements for the base printer configuration (110 volt). Power levels are
shown in watts.

Printing states

Lexmark
T630

Lexmark
T630n

Lexmark
T632

Lexmark
T632n

Lexmark
T634

Lexmark
T634n

Printing–average power
Base model

429 W

432 W

523 W

527 W

584 W

590 W

All options

457 W

460 W

540 W

544 W

608 W

614 W

Power Saver on

12 W

15 W

14 W

14 W

15 W

16 W

Power Saver off

81 W

84 W

81 W

84 W

86 W

87 W

Idle–average power

Printing–maximum current
110V

8.8 A

8.8 A

9.8 A

9.8 A

10.2 A

10.2 A

230V

4A

4A

5A

5A

5A

5A

Note: Using a 220 to 110 power converter with the 110 volt printer is not recommended.

Electrical specifications
Low voltage model
• 100 to 127 V ac at 50 to 60 Hz nominal
• 99 to 137 V ac, extreme
High voltage model
• 220 to 240 V ac at 50 to 60 Hz nominal (not available in all countries)
• 190 to 259 V ac, extreme

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Acoustics
All measurements are made in accordance with ISO 7779 and conform with ISO 9296.

1 Meter average
sound pressure

Declared sound
power

Model

Status

Lexmark T630(n)

Idle (standby mode)

31 dBA

4.6 Bels

Simplex printing

52 dBA

6.7 Bels

Duplex printing

55 dBA

N/M Bels

Idle (standby mode)

32 dBA

4.7 Bels

Simplex printing

54 dBA

6.8 Bels

Duplex printing

57 dBA

N/M Bels

Lexmark T632(n)

Lexmark T634(n)

Idle (standby mode)
Simplex printing
Duplex printing

Measurements apply to 300 dpi, 600 dpi, and 1200 dpi printing.

Environment
Printer temperature and humidity

• Operating
— Temperature: 16 to 32° C (60° to 90° F)
— Relative humidity: 8 to 80%
— Altitude: 10,000 ft. (0 to 3,048 meters)
• Storage and shipping environment (packaged)
— Temperature: -40° to 43° C (-40° to 110° F)
— Relative humidity: 5% to 95%
— Altitude: equivalent to 10,300 meters. (0 to 34,000 feet)
• Storage environment (unpacked)
— Temperature: 0° to 40° C (32° to 104° F)
— Relative humidity: 5% to 80%

General information

1-7

4060-xxx

Media specifications

x

Transparencies

x

x

Envelopes

1-8 Service Manual

Finisher to staple,
hole punch, offset stack
or with output bin

x

Output Expander

Card stock

5-Bin Mailbox

x

Standard output

x

Duplex

Multipurpose tray

Paper

Media type

2,000-Sheet drawer

500-Sheet input

Media type

x

x

x

x

x

x

x

x

x

x

x

x

Vinyl labels

x

x

Paper labels

x

x

Polyester labels

x

x

Dual web labels

x

x

x

Integrated labels

x

x

x

4060-xxx

2000-sheet drawer

Duplex

Standard output bin

Output Expander

5-Bin Mailbox

High-capacity output stacker

StapleSmart output bin

StapleSmart–Staple/jogger

x

x

x

x

x

x

x

x

x

x

x

x

A5 5.83 in. x 8.27 in.
(148 mm x 210 mm)

x

x

x

x

x

x

x

x

JIS-B5 7.17 in. x 10.23 in.
(182 mm x 257 mm)

x

x

x

x

x

x

x

x

x

x

x

Letter 8.5 in. x 11 in.
(216 mm x 279 mm)

x

x

x

x

x

x

x

x

x

x

x

x

Legal 8.5 in. x 14 in.
(216 mm x 355.6 mm)

x

x

x

x

x

x

x

x

x

x

x

x

Executive 7.25 in. x 10.5 in.
(184 mm x 267 mm)

x

x

x

x

x

x

x

x

x

x

x

Folio 8.5 in. x 13 in.
(216 mm x 330 mm) 1

x

x

x

x

x

x

x

x

x

x

Statement 5.5 in. x 8.5 in.
(140 mm x 216 mm) 1

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

Envelope feeder

Multipurpose tray

400 Universally adjustable tray

250 Input tray

A4 8.27 in. x 11.7 in.
(210 mm x 297 mm)

Media size supported

500 Input tray

Integrated tray

250 Universally adjustable tray

Media size

x

x

Universal 2
5.5 x 8.27 in. to 8.5 x 14 in. (139.7
x 210 mm to 215.9 x 355.6 mm)
2.75 x 5 in. to 8.5 x 14 in. (69.85 x
127 mm to 229 x 355.6 mm)
5.83 x 7.17 in. to 8.5 x 14 in. (148
x 182 mm to 215.9 x 355.6 mm)

x

x

x
x

x

x

x

x

1 This
2

size does not appear in the Paper Size menu until Tray Size Sensing is turned off.
This size setting formats the page for 215.9 x 355.6 mm (8.5 x 14 in.) unless the size is specified by the software
program.

General information

1-9

StapleSmart–Staple/jogger

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

10 Envelope 4.125 in. x 9.5 in.
(105 mm x 241 mm)

x

x

x

x

x

DL Envelope 4.33 in. x 8.66 in.
(110 mm x 220 mm)

x

x

x

x

x

C5 Envelope 6.38 in. x 9.01 in.
(162 mm x 229 mm)

x

x

x

x

x

B5 Envelope 6.93 in. x 9.84 in.
(176 mm x 250 mm)

x

x

x

x

x

x

x

x

x

x

x

x

x

x

x

5-Bin Mailbox

9 Envelope 3.875 in. x 8.9 in. (98
mm x 225.4 mm)

Duplex

x

Envelope feeder

x

2000-sheet drawer

x

Multipurpose tray

x

500 Input tray

x

250 Input tray

7¾ Envelope 3.875 in. x 7.5 in.
(98 mm x 191 mm)

Media size supported

Integrated tray

Output Expander

x

Standard output bin

StapleSmart output bin

High-capacity output stacker

400 Universally adjustable tray

250 Universally adjustable tray

4060-xxx

Envelopes

Other envelope
3.87 x 6.38 in. to 6.93 x 9.84 in.
(98.4 x 162 mm to 176 x 250 mm)
Media types
Paper

x

x

x

x

x

x

Card stock

x

x

x

x

x

x

Transparencies

x

x

x

x

x

x

Vinyl labels 3

x

x

x

x

x

x

x

x

x

x

x

x

x

x

Paper labels 3
Polyester labels

3

Dual web and integrated labels 3
3

x

x

Printing label application on the printer requires a special label fuser cleaner which prevents duplexing. The label
fuser cleaner is included with a special label cartridge for label applications.

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4060-xxx

Input media types and weights
Media weights–input
Media

Type

Weight

Integrated trays and optional 500-sheet drawers
Paper

Xerographic or business paper

60 to 176 g/m2 grain long
(16 to 47 lb bond)

Card stock–maximum
(grain long) 1

Index Bristol

163 g/m2 (90 lb bond)

Tag

163 g/m2 (100 lb bond)

Cover

176 g/m2 (65 lb bond)

Index Bristol

199 g/m2 (110 lb bond)

Tag

203 g/m2 (125 lb bond)

Cover

216 g/m2 (80 lb bond)

Transparencies

Laser printer

138 to 146 g/m2 (37 to 39 lb bond)

Labels–maximum 2

Paper

180 g/m2 (48 lb bond)

Dual-web paper

180 g/m2 (48 lb bond)

Polyester

220 g/m2 (59 lb bond)

Vinyl 3

300 g/m2 (92 lb liner)

Pressure sensitive area 2

140 to 175 g/m2

Paper base (grain long)

75 to 135 g/m2 (20 to 36 lb bond)

Card stock–maximum
(grain short) 1

Integrated forms

Multipurpose feeder and optional 250-sheet drawer
Paper

Xerographic or business paper

60 to 135 g/m2 grain long
(16 to 36 lb bond)

Card stock–maximum
(grain long) 1

Index Bristol

120 g/m2 (67 lb bond)

Tag

135 g/m2 (50 lb bond)

Cover

135 g/m2 (50 lb bond)

Index Bristol

163 g/m2 (90 lb bond)

Tag

163 g/m2 (100 lb bond)

Cover

176 g/m2 (65 lb bond)

Transparencies

Laser printer

138 to 146 g/m2 (37 to 39 lb bond)

Labels–maximum 2

Paper

163 g/m2 (43 lb bond)

Dual-web paper

163 g/m2 (43 lb bond)

Polyester

220 g/m2 (59 lb bond)

Vinyl 3

260 g/m2 (78 lb liner)

Card stock–maximum
(grain short) 1

General information

1-11

4060-xxx

Media weights–input (continued)
Media

Type

Weight

Integrated forms

Pressure sensitive area 2

140 to 175 g/m2

Paper base (grain long)

75 to 135 g/m2 (20 to 36 lb bond)

Sulfite, wood-free or up to 100%
cotton bond

60 to 105 g/m2
(16 to 28 lb bond) 3, 4

Sulfite, wood-free or up to 100%
cotton bond

60 to 105 g/m2
(16 to 28 lb bond) 3, 4

Xerographic or business paper

60 to 135 g/m2 grain long
(16 to 36 lb bond)

Envelope
Envelope feeder
Envelope
2000-sheet drawer
Paper
1
2
3
4
5

Grain short is preferred for paper over 135 g/m2.
Printing label applications on your printer requires a special label fuser cleaner which prevents duplexing.
28 lb bond envelopes are limited to 25% cotton content.
Includes envelopes fed from the multipurpose feeder only.
Information on whether your vinyl label converter has passed Lexmark’s criteria is available at Lexmark’s
Web site (www.lexmark.com). Search for “converter list.” You can also check Lexmark’s Automated Fax
system (LEXFAXSM).

Print area
The printable area is limited to within 4.2 mm (0.167 in.) of all edges of the media. Any information
placed outside this specified printable area does not print.

Media guidelines
Paper designed for use with xerographic copies should provide satisfactory print quality and feed
reliability. Other types of supplies may be suitable. We recommend that users test any particular
brand for suitability to their applications. Refer to the printer’s user information for additional media
specifications.

Paper
Use the following media guidelines for successful printing:

• Rough, highly textured, limp, or pre-curled paper results in lower print quality and more frequent
paper feed failures.

• Colored paper must be able to withstand 227° C (440° F) fusing temperature.
• Preprinted forms and letterheads should be selected using guidelines found in the printer’s user
information. The chemical process used in preprinting may render some papers unsuitable for
use with this printer.

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• Unsuitable papers include:
— Multi-part forms and documents
— Chemically treated papers
— Coated, synthetic, and thermal papers
— A5 paper less than 80 g/m2 (21 lb)
— Recycled paper less than 75 g/m2 (20 lb)
— Preprinted paper requiring a high degree of registration
• Recycled paper less than 80 g/m2 (21 lb) may cause unacceptable results.
Envelopes
• All envelopes should be new, unused, and without package damage.
• Envelopes with excessive curl or twist exceeding 6 mm, those stuck together, those with bent
corners or nicked edges, or those that interlock should not be used.

• Minimum weight should not be less than 75 g/m2 (20 lb).
• The following envelopes should not be used:
— Envelopes with windows, holes, perforations, cutouts, or deep embossing
— Envelopes with metal clasps, string ties, or metal folding bars
— Envelopes with exposed flap adhesive when the flap is in the closed position.
• For best results, printing on new 90 g/m2 (24 lb) sulfite or 25% cotton bond envelopes is
recommended.

• Under high humidity conditions (over 60%), envelopes may seal during printing.
Transparencies
• Use letter or A4-size transparencies only.
• Transparencies specifically designed for xerographic copy machines or laser printers may be
used with this printer.

Labels
Select labels using guidelines from in this printer’s user information, refer to the Card Stock and
Label Guide, or depend upon tested acceptability.

General information

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4060-xxx

Tools required
Flat-blade screwdrivers, various sizes
Phillips screwdrivers, various sizes
7.0 mm nut driver
5.5 mm wrench
Needlenose pliers
Diagonal side cutters
Spring hook
Feeler gauges
Analog or digital multimeter
Parallel wrap plug 1319128
Twinax/serial debug cable 1381963
Flash light (optional)

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4060-xxx

Acronyms
BLDC
CSU
DIMM
DRAM
DVM
EDO
EEPROM
EP
EPROM
ESD
FRU
GB
HCIT
HVPS
ITC
LASER
LCD
LED
LVPS
MPF
MROM
MS
NVRAM
OEM
OPT
PC
pel
POR
POST
PWM
RIP
ROM
SDRAM
SIMM
SRAM
UPR
V ac
V dc
VOM

Brushless DC motor
Customer setup
Dual Inline Memory Module
Dynamic Random Access Memory
Digital multimeter
Enhanced Data Out
Electrically Erasable Programable Read-Only Memory
Electrophotographic process
Erasable Programmable Read-Only Memory
Electrostatic Discharge
Field Replaceable Unit
Gigabyte
High-capacity Input Tray
High Voltage Power Supply
Internal Tray Card
Light Amplification by Stimulated Emission of Radiation
Liquid Crystal Display
Light-Emitting Diode
Low Voltage Power Supply
Multipurpose feeder
Masked Read Only Memory
Microswitch
Nonvolatile Random Access Memory
Original Equipment Manufacturer
Optical Sensor
Photoconductor
Picture element
Power-On Reset
Power-On Self Test
Pulse Width Modulation
Raster Imaging Processor
Read Only Memory
Synchronous Dynamic Random Access Memory
Single Inline Memory Module
Static Random Access Memory
Used Parts Return
Volts alternating current
Volts direct current
Volt Ohmmeter

General information

1-15

4060-xxx

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4060-xxx

2. Diagnostic information
Start
CAUTION: Remove the power cord from the printer or wall outlet before you connect or
disconnect any cable or electronic board or assembly for personal safety and to prevent
damage to the printer. Use the handholds on the side of the printer. Make sure your
fingers are not under the printer when you lift or set the printer down.
Use the service error code, user status message, user error message, symptom table, service
checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a
malfunctioning printer.
Service error codes are indicated by a three-digit error code. If a service error code displays, go to
“Service error codes” on page 2-2.
User status messages provide the user with information on the current status of the printer. Ready
displays on the first line of the display unless Power Saver is invoked, and then Power Saver displays.
If a user status message is displayed, go to “User status displays” on page 2-14.
User error messages are indicated by a two or three-digit error code that provides the user with
information that explains a problem with a print cartridge, paper jam, option, port, and so on. If a user
error message displays, go to “User attendance messages” on page 2-19.
If your machine completes the “Power-On Self Test (POST)” on page 2-34 without an error, and
you have a symptom, go to “Symptom tables” on page 2-35. Locate your symptom and take the
appropriate action.
If a service error code appears while you are working on the machine, go to “Service error codes”
on page 2-2 and take the indicated action for that error.

Diagnostic information

2-1

4060-xxx

Messages and error codes
Service error codes
Service error codes are generally non-recoverable except in an intermittent condition when you can
POR the printer to temporarily recover from the error condition.
Service error code
Error code

Action

900 RIP Software

Go to “900 Error Code service check” on page 2-41.

901 Engine Flash

Indicates that the flash which the system board code is programmed into is bad.
Replace the system board.

902 General Engine
Software Error

These errors indicate an unrecoverable system software error. Replace the
system board.

903 Paperport Link
Driver Error
904 Interface Violation
by RIP
905 Interface Violation
by Paperport Device
906 RIP Interface Driver
Error
910 DC Pick Motor DC
Pick Motor Stall

Error Codes 910, 911, 912, 913, and 914 are indications that a Tray 1 paper feed
problem has been detected. Go to “Input tray(s) service check” on page 2-64.

911 DC Pick Motor
Excessive PWM
912 DC Pick Motor
below speed
913 DC Pick Motor over
speed
914 DC Pick Motor: No
encoder feedback

Check the integrated paper tray (Tray 1) for correct paper loading. Reload the
paper and POR the printer. If the error continues, go to “Input tray(s) service
check” on page 2-64.

917 Transfer Roll

Indicates a problem in the transfer roll area. Go to “Transfer roll service check”
on page 2-94.

920 Fuser Error

Indicates that the fuser is below temperature when printing. Go to “Fuser service
checks” on page 2-52.

921 Fuser Error

Indicates that the fuser is below standby temperature when the printer is idle. Go
to “Fuser service checks” on page 2-52.

922 Fuser Error

Fuser failed to reach standby temperature. Go to “Fuser service checks” on
page 2-52.

923 Fuser Error

Fuser is too hot during printing or when printer is idle. Go to “Fuser service
checks” on page 2-52.

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4060-xxx

Service error code (continued)
Error code

Action

924 Fuser Error

An open circuit has been detected in the Fuser Thermistor Circuit. Go to “Fuser
service checks” on page 2-52.

925 Fuser Error

Wrong fuser lamp installed. Go to “Cold fuser service check” on page 2-52.

927 Fan Stalled

This is an indication that a printer fan has stalled. Go to “Main fan service
check” on page 2-69.

929 Toner Sensor

The toner sensor is not operating properly, the developer drive assembly is not
operating properly or the print cartridge is defective. Go to “Toner sensor service
check” on page 2-93.

930 Printhead Error

The wrong printhead may be installed. If you have not replaced the system board
recently, replace the correct printhead. If the problem remains, replace the system
board. If you have recently replaced the system board and you still have a 930
error, the wrong system board may be installed. Replace the system board with
the correct system board.

931-935 Printhead Error

These errors represent a problem with the printhead. Go to “Printhead service
check” on page 2-78.

932 - Printhead: Lost
Hsync
933 - Mirror Motor
Locks/Lost Hsync
934 - Mirror Motor Lost
Lock
935 - Mirror Motor
unable to reach
operating speed.
936-937 Transport
Motor

Indicates a problem with the main drive motor. Go to “Main drive service check”
on page 2-68.

936 - Main Drive Motor
initial lock failure
937 - Main Drive Motor
lost lock
940 Service LV Power
Supply

The low voltage power supply zero crossover test failed.
Check the LVPS for correct installation. Make sure the connector on the LVPS
assembly is firmly seated with the connector on the interconnect card connector.
This error may also be caused by a noisy AC input power source.
• Be sure the correct LVPS has been installed.
• If all the above are correct, replace the LVPS assembly.

948 PEL Clock Error

Indicates the pel clock check failed. Replace the system board.

949 Delay Line
Calibration Failure

Indicates a delay line calibration failure. Replace the system board.

950 NVRAM
Mismatch

Go to “950 Error Code service check” on page 2-42.

951 NVRAM
Secure NVRAM Missing

Replace the system board.

953 NVRAM Chip
Failure

Indicates the NVRAM chip on the interconnect board has failed. Replace the
interconnect board.

Diagnostic information

2-3

4060-xxx

Service error code (continued)
Error code

Action

954 NVRAM CRC
Failure

Indicates the NVRAM experienced a CRC failure. Replace the interconnect board.

955 Code CRC


Replace the system board. Where  = CRC Failure or ECC Failure on the
system board.

956, 957, 959 System
Board

Error codes 956 thru 959 are system board failures.
Perform a power on reset (POR). If this does not fix the problem, replace the
system board.
• 956 = Processor failure
• 957 = ASIC failure
• 959 = SRAM failure

958 NAND Failure

Before proceeding when a 958 NAND failure displays, perform a power on reset
(POR) to see if the ECC error correction code can reflash NAND.
If this does not fix the problem, replace the system board.

960 RAM Memory Error

Indicates a DRAM Memory Error on the system board. Replace the system board.

961 RAM in Slot 2 is
Bad

If another SDRAM memory DIMM is installed in slot 1, turn the power off, switch
the DIMM in slot 1 to slot 2. If the memory in slot 2 now works correctly, replace
the failing DIMM that was in slot 2. If this does not fix the problem, replace the
system board. If another DIMM is not available, replace the memory option. If this
does not fix the problem, replace the system board.

962 RAM in Slot 1 is
Bad

If another SDRAM memory DIMM is installed in slot 2, turn the power off, switch
the DIMM in slot 2 to slot 1. If the memory in slot 1 now works correctly, replace
the failing DIMM that was in slot 1. If this does not fix the problem, replace the
system board. If another DIMM is not available, replace the memory option. If this
does not fix the problem, replace the system board.

964 Emulation Error

Indicates a failure within the Download Emulation which is programmed into the
code overlay card. The specific error is as follows:
964 - Download Emulation CRC Failure. Checksum Failure. Go to “Disabling
Download Emulations” on page 3-3.

975 - 979 Network
Card x

The following errors indicate a failure with the network card in the specified slot.
(x=any card installed in slots 1 or 2.)
• 975 - Unrecognizable Network Card x. Replace network card x.
• 976 - Unrecoverable software error in network card x.
• 978 - Bad checksum while programming network card x. Replace network
card x.
• 979 - Flash parts failed while programming network card x.
If the printer is a network model, replace the system board.

980  Comm

The engine is experiencing unreliable communications to the specified device.

981 

The engine protocol violation detected by the specified device.

982  Comm

Communications error detected by the specified device.

983 

Invalid command received by the specified device.

984 

Invalid command parameter received by the specified device.
Note: Service errors 980 thru 984  can be one of the following: system
board, duplex, tray x (1, 2, 3, 4, or 5), envelope feeder or output bin.

2-4 Service Manual

4060-xxx

Service error code (continued)
Error code

Action

990 

Indicates an equipment check condition has occurred in the specified device, but
the device is unable to identify the exact component failure.
Note:  can be one of the following: duplex, tray x (1, 2, 3, 4, or 5),
envelope feeder or output bin.

991  Card

The specified device has detected an equipment check in its system card.
Note:  can be one of the following: duplex, tray x (1, 2, 3, 4, or 5),
envelope feeder or output bin.

Sub error codes
Sub error codes for 9xx and 2xx error codes
The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the
base printer, envelope feeder, and duplex option.
Displayed error codes
When a 9xx or 2xx error displays:

1. Press and hold Return and press Select to enter for sub error codes.
The first screen of information displays. Write down the information.

2. Continue pressing Return and Select until each screen of information is obtained.
3. When the last screen displays, the original message displays.
The following is an example of how the printer displays a duplex option sub error code.

DU
DU

Byte 1
xx
xx
Byte 5

Byte 2
xx
xx
Byte 6

Byte 3
xx
xx
Byte 7

Byte 4
xx
xx
Byte 8

Printed error codes
Additional information is available by printing the error log. See “Printing the error log” on
page 3-7.

Diagnostic information

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4060-xxx

Base printer sub error codes
Each status byte has a different level of troubleshooting value for each area of the printer. The
following table displays up to 8 status bytes of data. Some or all of these bytes may be used to help
diagnose a printer problem. These status bytes are designed to help isolate paper jams and paper
feed problems in the base printer.
Sub error code variable values
Displayed value of x

Printer area

Values for tray sources
10

Multipurpose Tray (MPT)

11

Tray 1

12

Tray 2

13

Tray 3

14

Tray 4

15

Tray 5

31

Envelope feeder

40

Manual feeder

Values for stacker destinations
91

Stacker 1

92

Stacker 2

93

Stacker 3

Values for media size
1

Letter

2

Legal

3

B5

4

A4

5

Executive

6

A5

7

Custom size

9

7¾ in. envelope

A

#9 Envelope

B

#10 Envelope

C

8.661 in. Envelope

D

C5 Envelope

E

B5 Envelope

F

Legal envelope

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4060-xxx

Base printer sub error codes
First 6 bytes sub error
code data (xx can be
any value)

Explanation

84 xx 00 x1 x2

This code indicates that the input sensor in the printer is still actuated from the first
sheet and the second sheet is ready to arrive at the sensor.
(x1=media size, x2=media source)
• Check the printer input sensor and flag for correct operation. The flag should
operate freely.
• Check for debris in the area of the input sensor.
• Check the area of the transfer plate and input to the fuser for anything that might
cause the paper to remain over the input sensor.

84 xx 01 x1

Video never started on the page.
(x1=media size)
The video signal never started within 2 inches after actuating the input sensor.
Check input sensor and flag.

84 xx 02 x1

This error is the most common type of paper jam. Possible causes are:
(x1=media size)
• Multi sheet feeding.
• A tray size sensing problem.
• The media feeding from the paper source is slipping or media is slipping in input
to the printer.

84 xx 04

The input sensor was covered during POST by a piece of media still in the
machine when it was turned on.
• Clear the media from the printer.
• Run the base sensor test (input sensor) from the diagnostic tests menu to test
the input sensor and flag for correct operation.

84 xx 05

There was media at the input sensor too early. There was not enough time
between printhead start and the printhead mirror motor to lock. Possible causes
for this error are:
• Paper might be pre-staged in the paper source tray.
• Paper is picking too fast.
• A defective input sensor.

84 00 06

A paper jam has been declared by a smart device. Immediate stop homing not
allowed.

84 00 07

A paper jam has been declared by a smart device. Homing was allowed before the
stop.

84 xx 0B x1 x2 x3

The option tray pass thru sensor was never actuated by a piece of media.
(x1=media size, x2=media source, and x3=paper source where paper jam was
detected)
• Run the sensor test for the option tray that is displaying the error code and
check the pass thru sensor for that tray for correct operation.
• Check for paper picking from the selected paper input source.
• If the error is being detected from a lower paper source, see if paper is feeding
correctly from a paper source above the detected source.

84 xx 0f x1 x2 x3

The option tray pass thru sensor was never deactivated.
(x1=media size, x2=media source, and x3=media source where paper jam was
detected)
• Check the pass thru sensor and flag for correct operation.
• Check to see if paper has cleared the pass thru area of the option where the
paper jam occurred.

84 00 10

The main motor ID failed to identify either motor after two tries. Possible causes for
this error are:
• The main drive motor has stalled.
• An incorrect main drive motor/gearbox assembly has been installed.

Diagnostic information

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4060-xxx

Base printer sub error codes (continued)
First 6 bytes sub error
code data (xx can be
any value)

Explanation

84 xx 17

There is an envelope or envelopes in the envelope feeder during warm up. An
envelope may have partially fed from the envelope feeder.
Remove any envelopes from the feeder and check the envelope feeder for correct
operation.

84 xx 18

There is media over the Tray 2 pass thru sensor during warm up. Check for media
over the sensor. If no media is present, check the pass thru sensor, flag, and
cables.
• Try running the Input Tray Tests for Tray 2 and see if Tray 2 is feeding paper
correctly and all the sensors are working correctly.
• Make sure the paper size setting is correct for the size paper in the tray.

84 xx 19

There is media over the Tray 3 pass thru sensor during warm up. Check for media
over the sensor. If no media is present, check the pass thru sensor, flag, and
cables.
• Try running the Input Tray Tests for Tray 3 and see if Tray 3 is feeding paper
correctly and all the sensors are working correctly.
• Make sure the paper size setting is correct for the size paper in the tray.

84 xx 1A

There is media over the Tray 4 pass thru sensor during warm up. Check for media
over the sensor. If no media is present, check the pass thru sensor, flag, and
cables.
• Try running the Input Tray Tests for Tray 4 and see if Tray 4 is feeding paper
correctly and all the sensors are working correctly.
• Make sure the paper size setting is correct for the size paper in the tray.

84 xx 1B

There is media over the Tray 5 pass thru sensor during warm up. Check for media
over the sensor. If no media is present, check the pass thru sensor, flag, and
cables.
• Try running the Input Tray Tests for Tray 5 and see if Tray 5 is feeding paper
correctly and all the sensors are working correctly.
• Make sure the paper size setting is correct for the size paper in the tray.

84 xx 1C

There is media over the Tray 6 pass thru sensor during warm up. Check for media
over the sensor. If no media is present, check the pass thru sensor, flag, and
cables.
• Try running the Input Tray Tests for Tray 6 and see if Tray 6 is feeding paper
correctly and all the sensors are working correctly.
• Make sure the paper size setting is correct for the size paper in the tray.

84 xx 1D

The envelope feeder pass thru sensor never deactivated. The display of this code
indicates that an envelope never crossed over the sensor flag and passed beyond
the sensor, or the flag and sensor are not operating properly. Go to “Envelope
feeder service check” on page 2-49.

84 xx 1E x1 x2

The envelope feeder pass thru sensor was never activated.
(x1=media size, x2=media source)
Make sure envelopes are feeding over the sensor. If an envelope feeds over the
sensor but the sensor does not activate, check the sensor and flag for correct
operation. If the sensor and flag are operating correctly, go to “Envelope feeder
service check” on page 2-49.

84 xx 20 x1 x2

The imaged page is not the expected page.
(x1=media size, x2=media source)
Check the pass thru sensor to make sure it is operating properly. If no problem is
found, it may be necessary to try a new pass thru sensor.

84 xx 21 x1 x2

The smart tray x did not pick a sheet of paper.
(x1=media size, x2=media source)
Check tray x auto compensator and tray parts for correct operation. If no problem
is found, go to “Input tray(s) service check” on page 2-64.

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4060-xxx

Base printer sub error codes (continued)
First 6 bytes sub error
code data (xx can be
any value)

Explanation

84 xx 22 x1 x2

This code indicates that the media activated the input sensor before the printer EP
was ready.
(x1=leading edge of media state, x2=trailing edge of media state)

84 xx 23 x1 x2

The transfer servo never started.
(x1=media size, x2=leading edge of media state)

84 xx 25

This code indicates that the media has activated the input sensor before the
printhead has locked. Enough time has elapsed since printhead start to expect a
lock.
One of the following may be failing:
• Printhead assembly
• System board
• Printhead cables

84 xx 26

This code indicates that media has activated the input sensor; however, the
printhead fell out of lock condition or not enough time elapsed since the printhead
start to expect a stable lock. The media may have also reached the input sensor
early.

89 00 01

The exit sensor in the fuser is activated by a piece of media indicating there is a
piece of media in the machine during POST.
Check for media in the exit of the fuser assembly or redrive assembly. Feed a
sheet of paper, and if the same error occurs after clearing the fuser or the same
error occurs when no media is present, check the exit sensor assembly, internal
fuser assembly cabling, DC fuser cable to the system board, and the cable
connection to J14 on the system board.
Service tip: Turn the printer off, enter the diagnostic tests menu, and select the
base sensor test. Select output sensor and check the sensor for correct operation.

89 xx 03

The fuser exit sensor did not detect the trailing edge of the media going through
the fuser assembly.
• This failure can be caused by a broken fuser exit sensor flag.
• This may also be caused by erratic operation of exit sensor flag or exit sensor or
a defective piece of media.

89 xx 04 x1

The fuser exit sensor never actuated from the sheet going through the fuser before
the next page begins feeding.
(x1=media size)

89 xx 07

The narrow media sensor in the fuser was covered by a sheet of paper when not
expected or a piece of media is in the machine during POST.
This error can occur when a 202 paper jam has occurred.
1. Remove any piece of media that is over the narrow media sensor.
2. Try to feed a piece of paper through the printer (could run the print test from the
diagnostic test menu). If the media stops over the narrow media sensor again,
check the flag and sensor for correct operation.

89 xx 0B x1

The fuser exit sensor may be bouncing.
This error can be caused by a failing exit sensor or system board.

89 xx 0D

The fuser exit sensor bounced. Check the exit sensor for correct operation. Check
the fuser DC cable to J14 on the system board. Also, the system board may be
failing.

Diagnostic information

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4060-xxx

Base printer sub error codes (continued)
First 6 bytes sub error
code data (xx can be
any value)

Explanation

8D 00 00

The fuser exit sensor was never activated by the leading edge of the media fed
through the printer.
• This error can be displayed after a 201 paper jam.
• This can be caused by a defective fuser exit sensor assembly.
Note: Enter the diagnostic tests menu, select Base Sensor Tests, select
Output Sensor Test and check the fuser exit sensor for correct operation. If
the test fails, check the internal fuser cabling, DC autoconnect on the fuser
frame, fuser DC autoconnect to the system board cable, and the cable
connection to J14 on the system board.

8E xx 02 x1 x2

This error can be caused by the input sensor not being activated by a page that
was known to have been picked by a source other than the duplex option.
Ensure the correct source has been selected and the media is feeding from that
source.

8E xx 06 x1

The second pick failed from a paper source when paper was in the source and the
only sheet in the paper path.

8E xx 07 x1

The second pick failed from a paper source when paper was in the source. Other
sheets may have started to feed, but none were in the paper path.

8E xx 08

The paper in the output bin was flushed. The paper ahead of it, in the paper path,
never made it past the output bin sensor or into the tray.

8E xx 09 x1

The second pick from the MPT, Tray 1, or feeder failed when paper was in the
source. Other sheets may be in the paper path.
(x1=media source)

8E xx 0A x1

The second pick from the MPT, Tray 1, or feeder failed when paper was in the
source. Other sheets may have started to pick, but none were in the paper path.
x1=media source)

8E x1 0B

The DC autocompensator failed or stalled when trying to feed a sheet of media.

8E xx 11

It took too long for the DC autocompensator motor to come up to speed.

8E xx 13 x1 x2

Late feeding from a paper source interfered with the next pick retry.
(x1=media size, x2=media source)

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4060-xxx

Base printer (fuser) sub error codes
The following sub error codes could help in diagnosing fuser assembly failures:
Base printer (fuser) sub error codes
First 6 bytes sub error
code data (xx can be
any value)

Explanation

920 Service - Fuser Error (under temperature while printing)
EN 08 xx yy - 1
EN- zz - - 2

xx=
yy=
zz=
zz=
zz=
zz=

00
01
02
03

Actual fuser temperature
The temperature that the fuser wants to reach.
The hot roll took too long to heat up.
The hot roll fell too far below the desired temperature while printing.
The hot roll was too cool while the system was doing some checking.
The hot roll was too cool when heating to the desired temperature.

921 Service - Fuser Error (fuser under temperature while at standby)
EN 41 xx yy -- 1
EN -- zz -- -- 2

xx=
Actual fuser temperature
yy=
The temperature that the fuser wants to reach.
zz= 00 The fuser temperature did not change enough from the fuser lamp
temperature at turn on.
01 The fuser temperature rose more than desired from the fuser
temperature at turn on.

922 Service - Fuser Error (fuser failed to reach standby temperature)
EN 42 xx yy -- 1
EN z1 z2 -- -- 2

xx=
Actual fuser temperature
yy=
The temperature that the fuser wants to reach.
zz= 00 The fuser temperature did not change enough from the fuser lamp
temperature at turn on.
01 The fuser temperature rose more than desired from the fuser
temperature at turn on.
z2= 00 The hot roll did not reach standby temperature in time during standby.
01 The hot roll took too long to reach the beginning lamp detection
temperature.
02 The hot roll reached ‘final lamp detection temperature’ but took longer
than expected.
03 The hot roll timed out trying to reach the ‘final lamp detection
temperature.’
04 After hot roll lamp detection, did not reach steady state control in time.
05 The hot roll did not reach operating temperature in time.

923 Service - Fuser Error (Fuser Cover Temperature)
EN 12 xx yy -- 1
EN -- -- -- -- 2

This sub error code displays anytime that the hot roll has reached a higher than
desired temperature.
xx=
Actual fuser temperature
yy=
The temperature that the fuser wants to reach.

924 Service - Fuser Error (Open Thermistor Failure)
EN 18 xx -- -- 1
EN -- 00 -- -- 2

This code is usually generated when an open circuit check is made of the
thermistor circuit in the fuser.
xx=
Actual Fuser Temperature

Diagnostic information

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4060-xxx

Base printer (fuser) sub error codes (continued)
First 6 bytes sub error
code data (xx can be
any value)

Explanation

925 Service - Fuser Error (Wrong Fuser Lamp Installed)
Note: The following sub error codes are only for an incorrect lamp being installed.
EN 07 xx yy zz 1
EN -- -- -- 2

This error code is generated anytime an incorrect lamp is detected.
xx= 00 Lamp detection performed and found an error.
01 It took long to do lamp detection and NVRAM detected a previous wrong
lamp detected.
yy=
Actual temperature
zz=
The temperature that the fuser was trying to reach.

Duplex option sub error codes
Status byte 4 contains the most valuable information to help isolate a failing part or assembly in the
duplex option and is the only byte contained in the following table.
Status byte 4

Explanation

00

No duplex error. No problem was reported to the engine by the duplex system
card.

01

The leading edge of the sheet of paper never arrived at the input sensor.

02

The duplex option system board never received media notification from the printer.

03

The trailing edge of the sheet of paper never cleared the input sensor.

04

The leading edge of the sheet of paper never arrived at the exit sensor.
Note: This error is the most common due to the long length of the paper path
between the input sensor and the exit sensor.

05

The duplex logic thinks a sheet of paper is feeding to the duplex option due to a
sensor malfunction in the paper path when in fact the printer has not sent a
command to send a sheet of paper to the duplex option.

06

The exit sensor detected a sheet of paper too early.

07

The sheet of paper trailing edge did not clear the exit sensor in the desired length
of time.

08

The feed motor experienced a complete motor stall.

0E

The DC motor is under speed. The motor never reached the correct operating
speed.

13

There is paper left in the duplex option. Paper was sensed during the homing
operation during POST.

15

There is paper left in the duplex option. Paper was sensed during the DC motor
diagnostic test during POST.

18

The DC motor experienced an acceleration error.

3D

There is paper left in the duplex option. Paper was sensed during IR clear during
POST.

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4060-xxx

Envelope feeder sub error codes
First 6 bytes sub error
code data (xx can be
any value)

Explanation

84 xx 17

There is an envelope in the feeder during POST.

84 xx 1D x1 x2

The envelope feeder pass thru sensor activated but never deactivated.
(x1=media size, x2=media source)
This error can be caused by an envelope over the pass thru sensor. Remove the
envelope and try to feed an envelope. If the envelope stops over the pass thru
sensor, try the following:
• Enter the diagnostic test menu, select Input Tray Sensor Tests, select
Envelope Feeder Sensor Test.
• Check the envelope pass thru sensor to ensure it is operating correctly. If the
sensor test fails, go to “Envelope feeder service check” on page 2-49.
If the test passes, look for anything that might cause the envelope to stop over the
sensor.

84 xx 1E x1 x2

An envelope never activated the envelope feeder pass thru sensor or the sensor
never sensed the presence of an envelope.
(x1=media size, x2=media source)
• Make sure the envelope feeds to the pass thru sensor.
• Check to see if the envelope actuates the pass thru sensor flag.

Diagnostic information

2-13

4060-xxx

User status displays
Each user status screen may also display a warning message. See “Warning messages (second
lines)” on page 2-16 for additional information when they display.
User status displays

Status

Action

Ready

The printer is ready to receive and
process data.

Press Menu to take the printer out of
Ready and enter all the menus except
the Tests Menu (Busy State).

The printer displays the fax status.

Press Menu to take the printer out of
Ready and enter all the menus except
the Tests Menu (Busy State).

The printer is ready and HEX Trace is
active, which is known as HEX Trace
Ready.

Press Menu to take the printer out of
Ready and enter the Tests Menu (Busy
State). Press Select for the values.
Press Menu until Reset Printer
displays on the second line. Press
Select to reset the printer.

When in the power saver mode the
printer displays this screen instead of
the ready screen. When a job is
received, the power saver screen
remains displayed until the printer exits
the power saver mode and the printer
warms up.

Press Menu to take the printer offline
and access the Ready Menu Group.



Ready





Ready

HEX



Power Saver

HEX



Power Saver





When the printer has been configured to
receive or send faxes the printer
displays this screen.

or
Press Go to take the printer out of
power saver and initiate a printer warm
up cycle.
or
Press Stop to take the printer offline.
Not Ready is displayed and no more
data is processed. Press Go to return
the printer to the previous state.

Res Reduced


Res Reduced 


2-14 Service Manual

The printer is processing data or
printing pages and the resolution of a
page belonging to the current job has
been reduced from 600 to 300 dpi to
prevent a Memory Full Error.
Displayed whenever the printer has
been configured to receive or send
faxes.

Press Stop to take the printer offline.
Not Ready is displayed, no more data
is processed, and the current job in the
paper path is processed. Press Go to
return the printer to the previous state.
or
Press Menu to access the Busy/
Waiting Menu. The following functions
may be available:
• Cancel Job
• Reset Printer
• Reset Active Bin
• Cancel FAX

4060-xxx

User status displays

Waiting




Status

Action

Displayed until the current job is
terminated or until additional data is
received on the active link. (PCL, PS,
PJL, PPDS, SIC, or HEX) may be
displayed for the value for interpreter if
the printer is not configured for fax.

Press Go to print the contents of the
printer buffer, staple the accumulated
sheets, or terminate the collation set.
Note: Go does not terminate the
current print job.

Press Menu to access the Busy/
Waiting Menu group. The following
functions may be available:
• Cancel Job
• Reset Printer
• Reset Active Bin
• Print Buffer.

Diagnostic information

2-15

4060-xxx

Warning messages (second lines)
These second line warnings apply to the User status displays (see “User status displays” on
page 2-14). For example,
Ready


If none of the conditions exist that are listed in the following table, line two is blank. If any of the
messages in the table are displayed, the following actions can be taken:

• Press Menu to take the printer offline and access the Ready Menu group. The Menu buttons are
not active if Menu Lockout is turned on.

• Press Stop to take the printer offline. The Not Ready message displays. No additional data is
processed from the host computer. Press Go to return the printer to the Ready state.
User message

Explanation

Toner Low

If the toner cartridge is low, then Toner Low displays. The Toner Low condition
clears whenever the upper front door is opened, and Toner Low displays again if
the condition exists after the upper front door is closed.

Tray x Missing

If any of the input trays equipped with tray present sensing are missing, then
Tray x Missing displays (where x designates which tray (1 through 5) is missing. If
multiple trays are missing, they are prioritized in this order: Tray 1, 2..., then Tray 5.
Tray x Missing status clears whenever Tray x is reinserted.
If the Tray 1 Missing message does not clear when tray 1 is inserted, go to
“Parallel port service check” on page 2-77. If Tray 2 through 5 Missing
message does not clear by inserting the tray, go to “Input tray(s) service check”
on page 2-64.

Tray x Empty

If any of the input trays are empty, then Tray x Empty displays, where x designates
which tray (Tray 1 through 5) is empty. If multiple trays are empty, then they are
prioritized in this order: Tray 5, Tray 4,...Tray 1.
Note: Tray x Empty status clears whenever Tray x is removed. When Tray x is
reinserted, it is examined and the appropriate status, if any, displays.
Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder.

Tray x Low

If any of the input trays are low, then “Tray x Low” displays, where x designates
which tray (1 through 5) is low. If multiple trays are low, they are prioritized in the
following order: Tray 5, 4, 3, 2, and 1.
Note: Tray x Low clears whenever tray x is empty, or tray x is removed. When
tray x is reinserted, it is examined and the appropriate status, if any, displays.
The printer cannot detect when the envelope feeder or multipurpose feeder are
low.

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4060-xxx

User status messages
User status messages

Status

Action

Busy

The printer is busy receiving or
processing data, or printing data.
Note: The printer indicator light blinks
while the printer is processing data.

Press Stop to take the printer out of
Busy status. Not Ready displays. No
additional data processes, but the
printer processes all paper currently in
the printer paper path. Press Go to
return to Ready.

Flushing Buffer

The printer is flushing corrupted print
data and the current print job is being
discarded.

No button actions are possible while
this message displays.

Printing Menu Settings

The printer is processing or printing a
list of current settings menus because
Print Menu Settings is selected from the
menu.

Press Stop to take the printer out of
Ready status. Not Ready displays. No
additional data is processed, but the
printer processes all paper currently in
the printer paper path. Press Go to
return to Ready status after the page
prints. Press Menu to take the printer
out of Ready and enter the Tests
Menu (Busy state). Press Select for
the values. Press Menu until Reset
Printer displays on the second line.
Press Select to reset the printer.

Printing Directory List

A directory of the flash and disk
contents is processing or printing
because Print Directory is selected from
the menu.

Press Stop to take the printer out of
Ready status. Not Ready displays. No
additional data is processed, but the
printer processes all paper currently in
the paper path. Press Go to return to
Ready after the page prints. Press
Menu to take the printer out of Ready
and enter the Tests Menu (Busy
state). Press Select for the values.
Press Menu until Reset Printer
displays on the second line. Press
Select to reset the printer.

The printer is restoring factory defaults.

No button actions are possible while
this message displays.

The printer is running the normal series
of start-up tests after it is powered on.
When the tests are complete, the printer
returns to Ready.

No button actions are possible while
this message displays.

The printer is in the Not Ready state,
which means it is not ready to receive or
process data. This message displays
when Menu is pressed during a print
job.

Press Go to take the printer out of the
Not Ready state. Press Menu to take
the printer out of Ready and enter the
Tests Menu (Busy state). Press Menu
until Reset Printer displays on the
second line. Press Select to reset the
printer.

The printer is deleting any print jobs in
process and restoring all settings to
user defaults.

No button actions are possible while
this message displays.

Restoring Factory Defaults

Performing Self Tests

Not Ready
(Press Go)

Resetting Printer

Diagnostic information

2-17

4060-xxx

User status messages

Status

Action

The flash memory is being formatted.

No button actions are possible while
this message displays.

The flash memory is being
programmed, which means fonts or
macros are being written to flash
memory.

Do not perform any button actions
while this message displays.

The disk is being formatted.

No button actions are possible while
this message displays.

The disk is being programmed, which
means fonts or macros are being written
to disk.

No button actions are possible while
this message displays.
Note: If information is written to flash
memory and to disk at the same time,
the Program Flash message displays.

The printer menus have been disabled.
This occurs when Menu is pressed
while the printer is Ready and Menu
Lockout is active. The printer display
shows this message for one second and
then returns to the Ready message.

No button actions are possible while
this message displays.

The printer is reset to activate a printer
setting changed in the menus.

No button actions are possible while
this message displays.

Formatting Flash
(Do Not Power Off)

Program Flash
(Do Not Power Off)

Formatting Disk

Programming Disk
(Do Not Power Off)

Menus Disabled

Activating Menu Changes

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4060-xxx

User attendance messages
User attendance messages
Primary message

Secondary message

Explanation

Change Cartridge
Invalid Refill

Select one of the following actions:
• Remove the toner cartridge and install a new
cartridge.
• Press and hold Select and press Return to display
debug data for the engine and cartridge code.
Note: This message may help diagnose a potential
printer problem.

Change 


This message displays when the user should change
the media installed in one of the input options.
• =Tray 1, Tray 2, Tray 3, Tray 4, Tray
5, MPF Feeder, Envelope Feeder.
• =Custom 1 through
Custom 6 using the MarkVision™ utility. When the
printer is prompting for one of the custom types
which has been named by the user, then only the
custom type name is displayed on line 2. The name
may be truncated to fit the display.

Change 


This message displays when the user should change
the media installed in one of the input options.
• =Tray 1, Tray 2, Tray 3, Tray 4, Tray
5, MPF Feeder, Envelope Feeder.
• = a user definable name.

Change 


This message displays when the user should change
the media installed in one of the input options:
• =Tray 1, Tray 2, Tray 3, Tray 4, Tray
5, MPF Feeder, Envelope Feeder.
• =letter, legal, B5, A4, Executive, Universal,
A5, B4, A3, 11x17, Folio, or Statement. For
envelopes, =7¾ Envelope, 9 Envelope,
10 Envelope, DL Envelope, C5 Envelope,
B5 Envelope, or other Envelope.

Change 


This message displays when the user should change
the media installed in one of the input options.
• =Tray 1, Tray 2, Tray 3, Tray 4, Tray
5, MPF Feeder, Envelope Feeder.
• =Bond, Card stock, Colored, Envelope,
Labels, Ltrhead, Plain, Preprint, or Transparency.
• =letter, legal, B5, A4, Executive, Universal,
A5, B4, A3, 11x17, Folio, or Statement. For
envelopes, =7¾ Envelope, 9 Envelope,
10 Envelope, DL Envelope, C5 Envelope,
B5 Envelope, or other Envelope.

Diagnostic information

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4060-xxx

User attendance messages (continued)
Primary message

Secondary message

Explanation

Check Duplex
Connection

This messages displays for the following conditions:
• The duplex option may have been removed from
the printer, possibly to clear a paper jam or to
remove the option.
• The duplex option may be attached to the printer
but a communications problem may prevent the
printer from detection. For example, there may be a
poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not
connected properly, reattach or reconnect it.
• Press Go to execute a configuration change which
notifies the printer the option has been hot
unplugged (removed with the power on).
Note: This action is not available if the printer is in
Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues to be displayed, go to “Duplex option
service check” on page 2-47.

Check Tray x
Connection

Tray x=Tray 2, Tray 3, Tray 4, or Tray 5
This messages displays for the following conditions:
• The specified device may have been removed from
the printer, possibly to clear a paper jam or to
uninstall the option.
• The option may be attached to the printer but a
communications problem may prevent the printer
from detecting the option. For example, there may
be a poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not
connected properly, reattach or reconnect it.
• Press Go to execute a configuration change which
notifies the printer the option has been hot
unplugged (removed with the power on).
Note: This action is not available if the printer is in
Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues to be displayed, go to “Input tray(s)
service check” on page 2-64.

Close Finisher Side
Door

Close the finisher side door. If the message does not
clear automatically when the door is closed, go to
“StapleSmart finisher service check” on page 2-86.

Close Finisher Top
Cover

Close the finisher top cover. If the message does not
clear automatically when the cover is closed, go to
“StapleSmart finisher service check” on page 2-86.

Delete All Jobs
Go/Stop?

When the user has selected the Print and Hold Delete
All Jobs selection, this message is displayed. The
following actions may be taken:
• Press Go to confirm the selection. All jobs are
deleted.
• Press Return or Stop to cancel the delete
operation.

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User attendance messages (continued)
Primary message

Secondary message

Explanation

Disk Corrupted
Reformat?

The printer has detected there are errors on the hard
disk that cannot be corrected. The disk cannot be used
until it is reformatted.
Warning: All data on the disk will be lost if you format
the disk.
The following actions can be taken:
• Power off and remove the disk. The disk will not be
formatted.
• Press Go to format the disk. All data is lost when
you format the disk.

Empty Box M

This message is displayed when the hole punch alarm
is on and the printer informed by the code the hole
punch box M is full. The following actions may be
taken:
• Empty the hole punch box.
• Press Go to ignore the message. The Box M Full
appears on line 2 of the display and the job is
printed without hole punching. The message
remains until the box is emptied.
If this message continues to be displayed when the
box has been emptied, go to “StapleSmart finisher
service check” on page 2-86.

Insert Box M

This message is displayed when the hole punch box is
missing or installed incorrectly. The message is
displayed during any of the following times, regardless
of the hole punch alarm setting:
• At POST
• After the finisher side door has been closed
• Before the first page of a job requesting hole
punch. The message displays once per job.
The following actions can be taken:
• Install the hole punch box.
• Press Go to ignore the message. The Box M
Missing message appears on the status line. A job
that is set for hole punching will not be punched.
The message continues to display on all
subsequent jobs that request hole punching.
If this message cannot be cleared after inserting the
box, go to “StapleSmart finisher service check” on
page 2-86.

Insert Cartridge or Close
Door

This message displays when the printer front door is
open or the print cartridge is missing.
If this message cannot be cleared, go to “Cover
closed switch/cable service check” on page 2-44.

Insert Staple Cartridge

This message displays when the staple cartridge is
missing or installed incorrectly. The message appears,
regardless of the Staple Alarm setting, at the following
times:
• At POR
• After the Stapler Door has been closed.
The following actions can be taken:
• Install the stapler cartridge.
• Press Go to clear the message. The printer
handles stapled jobs as if the staple cartridge were
installed, but empty. The Staples Empty message
appears on the status line and the Load Staples
may display.

Diagnostic information

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4060-xxx

User attendance messages (continued)
Primary message

Secondary message

Explanation

Insert 

=Tray 1, Tray 2, Tray 3, Tray 4, or Tray 5.
The printer detects a tray needs to be inserted. The
printer does not continue until it detects the tray is
inserted.
Note: This situation usually occurs when the tray is
refilled during a job. To refill a tray during a printing
session, press Stop and wait for pages to reach the
output bin before refilling the tray.
The following actions may be taken:
• Insert the requested tray.
• Press Menu until Busy/Waiting displays. The
following selections are available:
- Cancel Job
- Reset Printer
- Reset Active Bin
If the message cannot be cleared, go to “Internal tray
card/paper size sensing service check” on
page 2-66 or “Input tray(s) service check” on
page 2-64.

Install Bin x
or Cancel Job

Bin x=Bin 1, Bin 2, or Bin 3.
This message is displayed when a paper handling
option has been hot unplugged. The printer requires
the reinstallation of the option to print a page which
has been formatted by the interpreter before the option
was removed.
The following actions may be taken:
• Install the option.
• Press Menu until Busy/Waiting displays. Select
one of the following:
- Cancel Job
- Reset Printer
- Reset Active Bin
If the message cannot be cleared, go to “Input tray(s)
service check” on page 2-64.

Install Duplex
or Cancel Job

This message is displayed when a duplex option has
been hot unplugged. The printer requires the
reinstallation of the option to print a page which has
been formatted by the interpreter before the option
was removed.
The following actions may be taken:
• Install the duplex option.
• Press Menu until Busy/Waiting displays. Select
one of the following:
- Cancel Job
- Reset Printer
- Reset Active Bin
If the message cannot be cleared, go to “Duplex
option service check” on page 2-47.

Install Env Feed
or Cancel Job

This message is displayed when the envelope feeder
has been hot unplugged. The printer requires the
reinstallation of the feeder to print a page which has
been formatted by the interpreter before the feeder
was removed.
The following actions may be taken:
• Install the envelope feeder.
• Press Menu until Busy/Waiting displays. Select
one of the following:
- Cancel Job
- Reset Printer
- Reset Active Bin
If the message cannot be cleared, go to “Envelope
feeder service check” on page 2-49.

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User attendance messages (continued)
Primary message

Secondary message

Explanation

Install Tray x
or Cancel Job

Tray x=Tray 2, Tray 3, Tray 4, Tray 5.
This message is displayed when a paper handling
option has been hot unplugged. The printer requires
the reinstallation of the option to print a page which
has been formatted by the interpreter before the option
was removed.
The following actions may be taken:
• Install the option.
• Press Menu until Busy/Waiting displays. Select
one of the following:
- Cancel Job
- Reset Printer
- Reset Active Bin
If the message cannot be cleared, go to “Input tray(s)
service check” on page 2-64.

Load Staples

This message displays when the Staples Empty Alarm
is activated and one of the following occurs:
• There are no staples in the stapler.
• The maximum number of staples have been fired
after the engine has reported that the staple
cartridge is low.
• The printer does not detect the staple cartridge is
present.
The following actions may be taken:
• Install a new staple cartridge to clear this message
and select Start or Continue to resume printing
the staple job.
• Choose to ignore the Load Staples message for
this print job by pressing Go or Select. The printer
starts or resumes printing, but does not staple the
rest of the job.
• Press Menu until Busy/Waiting displays. The
following actions may be available:
- Cancel Job
- Reset Printer
- Reset Active Bin

Priming Failed
Retry. Go/Stop?

This message displays when an error has occurred
during the staple priming operation. This message not
only notifies the user that a specific error interfered
with the priming, but allows the user to request the
process begin again.
The following actions are available:
• Press Go to restart the priming operation.
• Press Return or Stop to cancel the priming
operation.

Diagnostic information

2-23

4060-xxx

User attendance messages (continued)
Primary message

Secondary message

Explanation

Reattach
Bins x–y

Bins x–y=Bins 1 to 5, Bins 2 to 6, or Bins 6 to 10
This messages displays for the following conditions:
• The specified output bins may have been removed
from the printer, possibly to clear a paper jam or to
remove the option.
• The option(s) may be attached to the printer but a
communications problem may prevent the printer
from detecting the option. For example, there may
be a poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not
connected properly, reattach or reconnect it.
• Press Go to execute a configuration change which
notifies the printer the option has been hot
unplugged (removed with the power on).
Note: This action is not available if the printer is in
Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues to be displayed, go to “Input tray(s)
service check” on page 2-64.

Reattach
Envelope Feeder

This messages displays for the following conditions:
• The feeder may have been removed from the
printer, possibly to clear a paper jam or to remove
the option.
• The feeder may be attached to the printer but a
communications problem may prevent the printer
from detecting the option. For example, there may
be a poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not
connected properly, reattach or reconnect it.
• Press Go to execute a configuration change which
notifies the printer the option has been hot
unplugged (removed with the power on).
Note: This action is not available if the printer is in
Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues to be displayed, go to “Envelope feeder
service check” on page 2-49.

Reattach
Output Bin x

Bin x=Bin 1, Bin 2, or Bin 3
This messages displays for the following conditions:
• The specified output bin may have been removed
from the printer, possibly to clear a paper jam or to
remove the option.
• The option may be attached to the printer but a
communications problem may prevent the printer
from detecting the option. For example, there may
be a poor connection or a hardware failure.
The following actions may be taken:
• If the option was temporarily removed or not
connected properly, reattach or reconnect it.
• Press Go to execute a configuration change which
notifies the printer the option has been hot
unplugged (removed with the power on).
Note: This action is not available if the printer is in
Diagnostics Mode or running diagnostics.
• If the device is experiencing a hardware problem,
turn the printer off and on. If the message
continues to be displayed, go to“Output expander
service check” on page 2-72.

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4060-xxx

User attendance messages (continued)
Primary message

Secondary message

Explanation

31 Defective Print
Cartridge

Error code 31 displays when the top front cover is
closed and a defective print cartridge is detected. It
may take the printer 10-20 seconds to determine if the
print cartridge is defective. Depending on the setting of
the Machine Class ID the printer may be allowed to
print pages during this 10-20 second interval. If pages
are allowed to print, they are not reprinted once a good
print cartridge is inserted.
Note: This error indicates the printer was able to read
the cartridge ID, but the ID did not pass the verification
test. To pass the verification test, the ID read from the
print cartridge must match the ID from the last “good”
print cartridge or the same ID must be read from the
print cartridge twice. The last “good” print cartridge ID
is stored in NVRAM.

32 Unsupported Print
Cartridge

Error 32 displays when the top cover is closed and an
unsupported print cartridge is detected. It may take the
printer 10-20 seconds to determine if the print
cartridge is supported. Depending on the setting of the
Machine Class ID the printer may be allowed to print
pages during this 10-20 second interval. If pages are
allowed to print, then they are not reprinted once a
good print cartridge is inserted. If this does not fix the
problem, go to “Smart contact assembly service
check” on page 2-85.

34 Short Paper

The printer determines the paper length is too short to
print the formatted data. This occurs when the printer
does not know the actual paper size loaded in the tray.
For auto-size sensing trays, this error occurs if the
paper stop is in the incorrect position. Make sure the
Paper Size setting is correct for the size paper that is
being used.

36 Resolution Reduced

The resolution of the page has been reduced from 600
dpi to 300 dpi to prevent a Memory Full error. This
message can only occur if the Resolution Reduction
setting is turned on.
Note: 1200 dpi pages are not resolution reduced. If a
1200 dpi job runs out of memory, a Memory Full error
displays.

37 Insufficient Collation
Area

This message displays when the printer memory is
insufficient to perform the Flash Memory Defragment
operation.
Note: This message is posted prior to the actual start
of the defragment operation. The printer code
determines if enough printer memory is available to
complete the defragment operation. The user should
not be concerned with losing resources stored in the
flash option.
The following actions may be taken:
• Press Go to clear the message. To perform the
defragment operation:
- Delete fonts, macros, and other data in RAM.
- Install additional printer memory.
• Press Menu until Busy/Waiting appears. The
following actions are available:
- Cancel Job
- Reset Printer
- Reset Active Bin

Diagnostic information

2-25

4060-xxx

User attendance messages (continued)
Primary message

Secondary message

Explanation

37 Insufficient Memory

Held Jobs may be lost

This message displays when the printer memory used
to restore the Print and Hold jobs from the disk and
found that some or all of the jobs could not be restored.
The printer ran out of memory while attempting to
restore the jobs.
• Press Go to clear the message. Some of the Print
and Hold jobs on the disk will not be restored. They
remain on the disk, but cannot be accessed.
• Press Menu until Busy/Waiting appears. The
following functions may be available:
- Cancel Job
- Reset Printer
- Reset Active Bin

38 Memory Full

This message displays when the printer is processing
an incoming job and there is insufficient memory
available to continue processing the job. The following
actions may be taken:
• Press Go to clear the message. Perform the
defragment operation:
- Perform the defragment operation
- Delete fonts, macros, and other data in RAM
- Install additional memory
• Press Menu to display Busy/Waiting. The following
functions may be available:
- Cancel Job
- Reset Printer
- Reset Active Bin

39 Complex Page

This message displays when the page is too complex
to print. The following actions may be taken:
• Press Go to clear the message and continue the
job. Some data loss may occur. Simplify the print
job and reprint, if necessary.
• Press Menu until Busy/Waiting appears. The
following selections are possible:
- Cancel Job
- Reset Printer
- Reset Active Bin

50 PPDS Font Error

This message displays when the PPDS interpreter has
encountered a font error.
Note: This error may only occur when the printer is
formatting PPDS print data.
The following actions may be taken:
• Press Go to clear the message and continue
processing the job.
• Press Menu until Busy/Waiting appears. The
following are available:
- Cancel Job
- Reset Printer
- Reset Active Bin

51 Defective Flash

This message displays when the printer detects a
defective flash. This error may occur at power on, or
during flash format and write operations. Press Go to
clear the message. The flash is marked as bad and
normal operation continues. Flash operations are not
allowed until the problem is resolved.

52 Flash Full

This message displays when there is not enough free
space in the flash memory to hold the resources that
have been requested to be written to flash.

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4060-xxx

User attendance messages (continued)
Primary message

Secondary message

Explanation

53 Unformatted Flash

This message displays when the printer detects an
unformatted flash at power on. Press Go to clear the
message. The flash is marked as bad and normal
operation continues. Flash operations are not allowed
until the flash is formatted.

54 Standard Network
Software Error

This error displays when a network port is detected,
but the printer cannot establish communications with it.

54 Network x
Software Error

This error displays when a network port is detected,
but the printer cannot establish communications with it.

55 Unsupported option
in Slot x

An unsupported option is installed in the specified
solutions port. Power off the printer and remove the
unsupported option in the specified slot.

55 Unsupported Flash in
Slot x

An unsupported flash option is installed in the
solutions port. Power off the printer and remove the
unsupported flash option in the specified slot.

56 Standard Serial
Disabled

This error displays when data is sent to the printer
across the standard serial port, but the port has been
disabled.

56 Serial Port x Disabled

This error displays when data is sent to the printer
across an optional parallel port, but the port has been
disabled. Once this message displays, reporting of
further errors is suppressed until the menus are
entered, or the printer is reset.

56 Standard USB Port
Disabled

Displayed when status is requested over the USB port,
but the port has been disabled. Once the error has
been displayed for the first time, reporting of further
errors is suppressed until the menus are entered or the
printer is reset.
The following actions may be taken:
• Press Go to clear the message. The printer
discards any data received on the USB port.
• Press Menu until Busy/Waiting appears. The
following are available:
- Reset Printer
- Reset Active Bin

56 Standard USB Port x
Disabled

Displayed when status is requested over the USB port
indicated, but the port has been disabled. Once the
error has been displayed for the first time, reporting of
further errors is suppressed until the menus are
entered or the printer is reset.
The following actions may be taken:
• Press Go to clear the message. The printer
discards any data received on the USB port.
• Press Menu until Busy/Waiting appears. The
following are available:
- Reset Printer
- Reset Active Bin

Diagnostic information

2-27

4060-xxx

User attendance messages (continued)
Primary message

Secondary message

Explanation

56 Standard Parallel
Port Disabled

This error is displayed when data is sent to the printer
across the parallel port, but the parallel port has been
disabled. Once this message is displayed, reporting of
further errors is suppressed until the menus are
entered, or the printer is reset. The following actions
may be taken:
• Press Go to clear the message. The printer
discards any data received on the parallel port.
• Press Menu until Busy/Waiting appears. The
following are available:
- Reset Printer
- Reset Active Bin

56 Parallel Port x
Disabled

This error is displayed when data is sent to the printer
across the parallel port, but the parallel port indicated
has been disabled. Once this message is displayed,
reporting of further errors is suppressed until the
menus are entered, or the printer is reset. The
following actions may be taken:
• Press Go to clear the message. The printer
discards any data received on the parallel port.
• Press Menu until Busy/Waiting appears. The
following are available:
- Reset Printer
- Reset Active Bin

57 Configuration
Change

The printer has attempted to restore the Print and Hold
jobs from the disk and found that some or all of the
jobs could not be restored. The printer could not
restore jobs from the disk because the configuration of
the printer has changed. This message alternates with
the secondary message, “Held jobs may not be
restored.”
Some configuration changes that may cause this
condition are:
• Code version change
• Paper handling option is removed
• Disk has been moved to a different model printer.
Press Go to clear the message. Some of the Print and
Hold jobs stored on the disk will not be restored. They
remain on the disk, but cannot be accessed.

58 Too Many Trays
Attached

This error code displays when too many input trays are
attached to the printer.

58 Too Many Disks
Installed

This error displays when too many disks are attached
to the printer.

59 Incompatible Output
Bin x

An incompatible output bin is installed. For Output Bin
x, x=1, 2, or 3.
Remove the incompatible output bin and press Go to
clear the message.
Note: If the user installed the incompatible device to
satisfy a Check Device Connections/reattach
message, the user should reinstall an associated
compatible option or hot unplug the option.

59 Incompatible
Envelope Feeder

An incompatible envelope feeder is installed.
Remove the incompatible feeder and press Go to clear
the message.
Note: If the user installed the incompatible device to
satisfy a Check Device Connections/reattach
message, the user should reinstall an associated
compatible option or hot unplug the option.

2-28 Service Manual

4060-xxx

User attendance messages (continued)
Primary message

Secondary message

Explanation

59 Incompatible Tray x

An incompatible tray is installed. For Tray x, x= 2, 3, 4,
or 5.
Remove the incompatible tray and press Go to clear
the message.
Note: If the user installed the incompatible device to
satisfy a Check Device Connections/reattach
message, the user should reinstall an associated
compatible option or hot unplug the option.

59 Incompatible Duplex

An incompatible duplex option is installed.
Remove the incompatible duplex option and press Go
to clear the message.
Note: If the user installed the incompatible device to
satisfy a Check Device Connections/reattach
message, the user should reinstall an associated
compatible option or hot unplug the option.

61 Defective Disk

This error code displays when the printer detects a
defective disk. This error may occur at power on or
during disk format and write operations. While this
message displays, press Go to clear the message.
The disk is marked defective and normal printer
operations continue. Disk operations are not allowed
with a defective disk. The Format Disk menu is not
shown.

62 Disk Full

This error code displays when there is not enough free
space on the disk to hold the resources that have been
requested to be written to the disk. This message
displays for both resource and PostScript Disk
operators when the disk is full.

63 Unformatted Disk

This error code displays when the printer detects an
unformatted disk at power on. Press Go to clear the
message. The disk is marked as bad and normal
operation continues. Disk operations are not allowed
until the disk is formatted.

64 Unsupported Disk
Format

The printer detects an unsupported disk format at
POR.
Press Go to clear the message. The disk is marked as
bad and normal operation continues. Further disk
operations are not allowed until the disk is formatted.

80 Scheduled
Maintenance

The operator panel displays this message at each
300K page count interval. It is necessary to replace
the fuser assembly, transfer roller, charge roll, and pick
rolls at this interval to maintain the print quality and
reliability of the printer. The parts are available as a
maintenance kit. For more information, go to
“Scheduled maintenance” on page 6-1.

81 Engine Code CRC
Failure

This error displays when the microcode to be
programmed in the engine flash code module has
failed a CRC check. Press Go to clear the message.
The microcode data is discarded and must be retransmitted from the host computer.

88 Toner Low

This message displays when toner low occurs and the
toner low alarm is activated. Press Go to clear this
message.

Diagnostic information

2-29

4060-xxx

User attendance messages (continued)
Primary message

Secondary message

Explanation

200 Paper Jam
Remove Cartridge

Leave Job in Finisher

Primary: Paper is jammed at the printer input sensor.
Open the printer upper front door and remove the print
cartridge to access the paper jam area.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

201 Paper Jam
Remove Cartridge

Leave Job in Finisher

Primary: Paper is jammed between the printer input
and exit sensors. Open the printer upper front door and
remove the print cartridge to access the jam area.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

202 Paper Jam
Open Rear Door

Leave Job in Finisher

Primary: Paper is jammed at the printer exit sensor.
Open the printer rear door to access the jam area.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

231 Duplex Paper Jam Rear

Leave Job in Finisher

Primary: A piece of media did not arrive at the duplex
input sensor, but did leave the printer exit sensor.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

232 Duplex Paper Jam Rear

Leave Job in Finisher

Primary: A piece of media did not clear the duplex
input sensor but did leave the printer exit sensor.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

233 Duplex Paper Jam Rear

Leave Job in Finisher

Primary: A piece of media failed to make the duplex
double feed sensor during turnaround.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

234 Duplex Paper Jam Rear

Leave Job in Finisher

Primary: The media did not reach the duplex exit
sensor.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

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User attendance messages (continued)
Primary message

Secondary message

Explanation

235 Duplex Paper Jam Front

Leave Job in Finisher

Primary: A piece of media is over the duplex double
feed sensor.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

236 Duplex Paper Jam Front

Leave Job in Finisher

Primary: A piece of media did not leave the duplex exit
sensor.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

237 Duplex Paper Jam Front

Leave Job in Finisher

Primary: A piece of media did not reach the printer
input sensor.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

238 Duplex Paper Jam

Leave Job in Finisher

Primary: A piece of media is over one of the duplex
sensors during a reset.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

239 Duplex Paper Jam

Leave Job in Finisher

Primary: A paper jam has occurred in the duplex
option.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

24x Paper Jam
Check Tray x

Paper is jammed around Tray x.
(x=tray 1 thru 5)
Try opening Tray x. If the tray is difficult to remove, then
you may have to remove the tray above or below tray x
to remove the jammed pages.

250 Paper Jam
Check MP Feeder

Paper is jammed in the multipurpose feeder.

260 Paper Jam
Check Envelope Feeder

Paper is jammed in the envelope feeder.

27x Paper Jam
Check Output

Paper is jammed in output bin. Open the rear door to
access the jammed pages.

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User attendance messages (continued)
Primary message

Secondary message

Explanation

280 Paper Jam
Check Finisher

Leave Job in Finisher

Primary: Paper is jammed in the finisher option. Open
the finisher option side door or top cover to access the
jammed pages.
Secondary: When this message is displayed, do not
remove accumulated sheets during the jam clearance
procedure as the printer will not reprint the removed
sheets. Also, if the accumulated sheets are removed,
the portion of the job printed after the jam will not be
stapled.

281 Paper Jam
Check Finisher

Remove Job from
Finisher

Primary: Paper is jammed in the finisher option. Open
the finisher option side door or top cover to access the
jammed pages.
Secondary: When this message is displayed, remove
the job from the finisher. The printed will not reprint the
removed sheets.

282 Staple Jam
Check Stapler

Remove Job from
Finisher

Primary: A staple jam has been detected during
normal stapler operation.
Secondary: The printer flashes the secondary
message to indicate that all accumulated sheets
should be removed during the jam clearance.

283 Staple Jam
Check Stapler

A staple jam has been detected during the priming
operation.
Note: Press Go to initiate priming and resume printing
while either of the primary or secondary messages
displays.

1565 Emul Error
Load Emul Option

This message appears when the IPDS emulation
version contained in the SIMM does not function with
the printer code. This message automatically clears in
30 seconds, and the IPDS emulation is disabled. No
other printer functions are affected. The correct IPDS
emulation must be downloaded.

User line 2 link messages
If the printer is locked on a particular link, the link indication displays. If the printer is ready to process
any link, no messages display. Link messages are listed in the following table.
User message

Explanation

Parallel

Standard Parallel Port, if available.

Serial

Standard Serial Port, if available.

Serial x

Serial Port is attached to PCI connector x, where x=1, 2, or 3.

Network x

Network card x is attached to PCI connector x, where x=1, 2, or 3.

LocalTalk x

LocalTalk Card x is attached to PCI connector x, where x=1, 2, or 3.

Infrared

Standard Infrared port, if available.

Infrared x

Infrared Port x is attached to PCI connector x, x=1, 2, or 3.

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Check device connection messages
The messages in the following table display when the printer loses communications with one of the
following devices.
User status message

Explanation

Check Env Feeder
Connection

Check envelope feeder connection.

Check Tray x
Connection

Check tray x, where x=1, 2, 3, 4, or 5.

Check Duplex
Connection

Check duplex option connection.

The messages in the following table can occur in two ways. The specified device could have been
removed from the printer, for instance to clear a paper jam. Otherwise, the device can still be
attached to the printer, but is experiencing a communications problem, not fully connected, or having
a hardware failure.
If the device is temporarily removed or not connected properly, then the user is advised to reattach it.
When the option is recognized, the printer automatically clears the error and continues. If the option
is experiencing a hardware problem, turn the printer off and back on. If the error occurs again, the
user is advised to turn the printer off, remove the option, and call for service.
User status message

Explanation

Turn Printer OFF to
Enable Option

A printer option, Input Tray, or Envelope Feeder, has been attached while the
printer is powered on. To use the option, the printer must first be powered off and
back on again. Data loss results if print jobs are active when the printer is power
cycled. If a print job is active, then remove the option and finish the job. The printer
automatically clears the message once the option is removed. Once the job is
complete, turn off the printer and attach the option again.

Insert Duplex Front
Cover

The duplex front access cover is not installed.

Close Duplex Rear Door

The duplex rear door is open.

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Power-On Self Test (POST)
When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning
of the base printer by observing the following:

1.
2.
3.
4.
5.

The LED comes on.
The operator panel displays one and a half row of pels, and then clears.
Diamonds scroll across the display, and then clear.
The operator panel displays one and a half row of pels, and then clears.
The top line of the operator panel displays one square block of pels that turn on one at a time
until all sixteen blocks display and then they all turn off.
For example:
*
32MB

350 Mhz

6. Performing Self Test appears on the display.
• The high-capacity option elevator tray moves to the uppermost position if installed.
• The duplex option is checked if installed.
7. Busy appears on the display.

8.
9.
10.
11.
12.
13.
14.

If present, the following errors or messages may display:
• Close Door or Insert Cartridge display if the upper front cover is open or the print cartridge
is missing.
• Any cartridge errors, such as Defective Cartridge, Prebate Violation, or Missing Cartridge.
The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm start.
The main fan turns on.
The main drive motor turns on.
The developer drive assembly drives the developer shaft in the toner cartridge.
The exit rollers turn.
The operator panel LED starts blinking.
Ready appears on the display.

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Symptom tables
Base printer symptoms
Symptom

Action

Dead machine

Go to “Dead machine service check” on page 2-45.

Operator panel–one or more buttons do
not work.

Go to “Operator panel buttons service check” on page 2-70.

Operator panel–display is blank. Printer
sounds 5 beeps.

Go to “Operator panel service check” on page 2-70.

Operator panel–display is blank. Printer
does not sound 5 beeps.

Replace the operator panel assembly.

Operator panel continuously displays all
diamonds, sounds 5 beeps, and does not
complete POST.

Go to “Operator panel service check” on page 2-70.

Paper feed problems–base printer or
integrated 500-sheet paper tray

Go to “Paper feed service check” on page 2-76.

Paper jams at exit of redrive assembly–
duplex option not installed.

Go to “Paper feed service check” on page 2-76.

Paper jams at exit of redrive assembly–
duplex option installed.

Go to “Duplex option service check” on page 2-47.

Fuser solenoid fails to operate.

Go to “Fuser solenoid service check” on page 2-55.

Print quality–black page

Go to “Print quality–all black page” on page 2-79.

Print quality–blank page

Go to “Print quality–blank page.” on page 2-79.

Print quality–light print

Go to “Print quality–light print” on page 2-84.

Print quality–background

Go to “Print quality–background” on page 2-82.

Print quality–residual image

Go to “Print quality–residual image” on page 2-83.

Print quality–skew

Go to “Paper feed service check” on page 2-76.

Print quality–banding

Go to “Print quality–banding” on page 2-83.

Print quality–random marks

Go to “Print quality–random marks” on page 2-80.

Print quality–toner on backside of printed
page.

Go to “Print quality–toner on backside of printed page” on
page 2-84.

Print quality–vertical black bands on edge
of copy.

Go to “Print quality–black bands on outer edges of the
page” on page 2-83.

Unable to clear a 32-Unsupported Print
Cartridge user error message.

Go to “Smart contact assembly service check” on
page 2-85.

High-capacity feeder (2000-sheet) symptoms
Symptom

Action

The printer does not recognize the highcapacity feeder installed.

Go to “High-capacity feeder input tray service check” on
page 2-56.

Paper feed problem with the high-capacity
feeder.

Go to “High-capacity feeder input tray service check” on
page 2-56.

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Paper tray symptoms
Symptom

Action

Paper feed problem with 250-Sheet Paper
Tray.

Go to “Input tray(s) service check” on page 2-64.

Paper feed problem with 500-Sheet Paper
Tray.

Go to “Input tray(s) service check” on page 2-64.

Media fails to pass through from the lower
attached Paper Tray option to the next
higher mounted option.

Go to “Input tray(s) service check” on page 2-64.

Duplex option symptoms
Symptom

Action

Paper feed problem with Duplex.

Go to “Duplex option service check” on page 2-47.

Paper jams at Paper Removal Tray.

Go to “Duplex option service check” on page 2-47.

Paper skews in the Duplex Option.

Go to “Duplex option service check” on page 2-47.

Paper fails to pass from lower option
through the Duplex Option.

Go to “Duplex option service check” on page 2-47.

Envelope feeder symptoms
Symptom

Action

Envelopes do not feed from the envelope
feeder.

Go to “Envelope feeder service check” on page 2-49.

Envelopes do not feed properly into base
printer.

Go to “Envelope feeder service check” on page 2-49.

Output expander
Symptom

Action

Printer does not display Output Bin Full.

Go to “Output bin sensor standard tray service check” on
page 2-72.

Paper does not feed all the way into the
output tray.

Go to “Output expander service check” on page 2-72.

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StapleSmart finisher
Symptom

Action

Finisher does not staple.

Go to “StapleSmart finisher service check” on page 2-86.

Printer does not recognize StapleSmart
Finisher Option as being installed.

Go to “StapleSmart finisher service check” on page 2-86.

Close Top Cover displayed. Unable to clear
or reset message (POST incomplete).

Go to “StapleSmart finisher service check” on page 2-86.

Close Finisher Side Cover displayed.
Unable to clear or reset message (POST
incomplete).

Go to “StapleSmart finisher service check” on page 2-86.

Paper feeds into finisher option output tray.
Paper is not stapled and paper does not
align with the right side.

Go to “StapleSmart finisher service check” on page 2-86.

Paper feeds into finisher option. Paper
aligns with the right side. The stapler does
not staple.

Go to “StapleSmart finisher service check” on page 2-86.

Paper is transported into the output tray but
is not stapled.

Go to “StapleSmart finisher service check” on page 2-86.

Stapled sheets are not transported to the
output tray.

Go to “StapleSmart finisher service check” on page 2-86.

Diagnostic information

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Service Checks
Anytime the system board is replaced, the Configuration ID must be reset in NVRAM. Go to “Setting
configuration ID” on page 3-18.
Review the following information before performing any service checks.

• Paper feed problems (especially paper jams): Go to “Viewing the error log” on page 3-6 and
check the printer error log for indications of repetitive entries that help to isolate a problem to a
particular area of the printer or option.
Paper feed problems with error message: Use the “Sub error codes for 9xx and 2xx error
codes” on page 2-5 to help diagnose the problem.
Print quality problems: Go to “Print quality test pages” on page 3-20 and print a test page to
help diagnose problems before changing any settings or working on the printer.
Use the resident diagnostics test provided to help isolate a problem before taking the machine
apart or removing any options.

•
•
•

5-Bin mailbox service check
Service tip: The majority of the mechanical components can be observed during operation by
removing the left and right side covers.
Make sure the option(s) are correctly installed and the machine is configured correctly before
attempting to service the unit.

Problems with excessive static electricity buildup.

1

FRU

Action

Front cover assembly

Check the front cover assembly to make sure the ESD brush ground
lead is firmly attached to the 5-Bin mailbox frame. Also check to
make sure the ESD brush is not loose or damaged.

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The printer does not recognize one or more output options as installed.
Service tip: If more than a single output option is installed, check each one to see if the printer
recognizes any single option as being installed. If the printer recognizes any of the output options
then the base printer autoconnect system is operating correctly and the problem is in the
unrecognized option. Continue with this service check or go to the service check for the failing output
option.
FRU

Action

1

5-Bin mailbox option

Check the autoconnects, cables, and connectors of the option for any
signs of loose or damaged parts.

2

Mechanical linkage
assembly

Remove the left and right side covers and check the two
autoconnects for damage, especially the connector pins. Remove the
output option and check the voltages on the standard output bin
autoconnect located on the top left rear of the printer. Go to
“Autoconnect” on page 5-1. If the voltages are correct, reinstall the
output option noting the position of the toroid on the autoconnect
cable of the lower autoconnect. Check the voltages on each of the
autoconnects. If the toroid was moved, make sure to move it back to
its original position on the cable. If the voltages are correct, replace
the control board. If the voltages are incorrect, replace the failing
autoconnect assembly.

271 Paper Jam - Check Bin 1 displays

1

FRU

Action

Bottom pass thru sensor
flag assembly
Control board

Check the flag for correct operation, binding, broken parts, or
interference from the sensor cable. If incorrect, repair as necessary. If
correct, make sure the bottom pass thru sensor is correctly
connected to J5 on the control board. Disconnect the pass thru
sensor cable and check the voltage at J5-3. The voltage measures
approximately +5 V dc. If incorrect, check the voltage at J5-2. The
voltage measures approximately 0 V dc. If incorrect, replace the
sensor assembly. If this does not fix the problem, replace the control
board.

274 Paper Jam - Check Bin 4 displays
Service tip: When a 274 Paper Jam Check Bin 4 message displays, a problem exists with the top
pass thru sensor assembly or the control board.

1

FRU

Action

Top pass thru sensor flag
assembly
Control board

Check the flag for correct operation, binding, broken parts or
interference from the sensor cable. If incorrect, repair as necessary. If
correct check to make sure the top pass thru sensor is correctly
connected to J11 on the control board. Disconnect the pass thru
sensor cable and check the voltage at J11-3 The voltage measures
approximately +5 V dc. If incorrect, check the voltage at J11-2. The
voltage measures approximately 0 V dc. If incorrect, replace the
sensor assembly. If this does not fix the problem, replace the lower
control board.

Diagnostic information

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Ready Bin x Full displays–May be able to clear message and feed paper into
bin selected.

1

FRU

Action

Bin x sensor
Bin x sensor cable
Bin x sensor flag
Control board

Check the sensor and sensor cable for the bin that is displaying the
message to make sure the sensor is seated correctly in the side of
the tray and the cable is connected to the sensor and the control
board. Check the flag for binding and proper operation. If correct,
replace the bin x sensor. If this does not fix the problem, replace the
control board.
Note: This sensor is in a normally open position with the flag out of
the sensor slot.

Bin x is full–message that Bin x is Full does not display.

1

FRU

Action

Bin x sensor
Bin x sensor cable
Bin x sensor flag
Bin x sensor flag
Control board

Check the sensor flag for binds, broken or missing parts. If correct,
check the bin sensor for correct installation in the side of the tray. If
the bin sensor is installed correctly, check the sensor cable for correct
installation to the sensor and control board. If correct, replace the
bin x sensor. If this does not fix the problem, replace the control
board.

Ready–Bin x Full displays and paper feeds into bin x.

1

FRU

Action

Bin x sensor
Bin x sensor control board

Check the sensor flag for binds. Make sure the sensor flag is not in
an up position. If the sensor flag is operating correctly, replace the bin
x sensor. If this does not fix the problem, replace the control board.

271 Paper Jam - Check Bin 1 displays–paper does not feed into the bin
selected
FRU

Action

1

Deflector
Deflector spring
Deflector cover
Deflector cover spring
Shaft assemblies

Check all the bin parts for missing or loose springs, binds in the
deflector or deflector cover, broken or binding shaft assemblies, or
broken gear teeth. If incorrect, repair as necessary.

2

Bin x solenoid assembly
Control board

Check the solenoid for any binds. Make sure the solenoid is
contacting the latch correctly. If incorrect, repair as necessary. If the
solenoid appears to be operating mechanically, check the resistance
of the solenoid. It measures between 30 and 50 ohms. If incorrect,
replace the failing solenoid assembly. If correct, replace the control
board.

3

Mechanical linkage
Motor assembly

If the DC motor is functioning properly, check the gears, clutch, and
other linkage parts for correct operation and wear, broken gear teeth,
or damaged parts. If incorrect, replace the mechanical linkage
assembly/DC motor assembly.

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990 Service Error displays
FRU

Action

1

Mechanical linkage
DC motor assembly

Check the DC motor cable connector to be sure it is correctly
installed at J2 on the control board. If correct, disconnect J2 from the
control board and check the resistance of the motor on the cable
connector. J2-1 to J2-2 measures between 115 and 135 ohms. Also
check J2-1 and J2-4 to the motor case for shorts. If either the
resistance is incorrect or a short is found, replace the mechanical
linkage/DC motor assembly.
Note: If the DC motor is shorted, it may also be necessary to replace
the control board.

2

Control board

Disconnect the motor cable J2 from the control board and check the
voltages at J2 on the board.
Warning: Use caution not to short adjacent pins on the connector as
damage to the board could result.
Pin

Measured (motor idle)

J2-1

+24 V dc

J2-2

+24 V dc

J2-5

+5 V dc

J2-6

+5 V dc

If any of the voltages are incorrect, replace the control board. If
correct, replace the mechanical linkage/ DC motor assembly.

900 Error Code service check
FRU

Action

1

Printer POR

Turn the printer off and on several times. If Error Code 900 continues
to display, go to step 2.

2

System board

Make sure the system board is properly seated in connector J7 on
the interconnect board.
Turn the machine off and on several times, waiting a few minutes
between power on and power off.
If Error Code 900 continues to display, go to step 3.

3

Factory defaults

Restore factory defaults. See “Restore EP Factory Defaults” on
page 3-18. This resets the non-critical areas of the user NVRAM. If
Error Code 900 continues to display, go to step 4.

4

Sub error codes

With Error Code 900 displayed, press Select and Return. Record the
complete list of Sub Error Codes on the display. Check the “Base
printer sub error codes” on page 2-6. If none of the Sub Error
Codes are listed, then call your next level of support or call Lexmark.

Diagnostic information

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950 Error Code service check
Note: Before proceeding with this service check, make sure you have the correct system board
installed in the printer.

950 Error displayed on the printer and you are not sure if the printer had the
interconnect or system boards previously replaced.

1

FRU

Action

Interconnect board

Note: Before replacing the interconnect board, make absolutely sure
you have the correct FRU number for the interconnect board that
should go into your printer.
Warning: Any time the interconnect board assembly is replaced, the
Configuration ID must be reset in NVRAM on the interconnect board.
See “Setting configuration ID” on page 3-18.
Unplug the machine and replace the interconnect board assembly.
Turn the printer on. If a 950 error still displays, replace the system
board assembly.

950 Error after replacing the system board

1

FRU

Action

System board

Note: Make sure you have the correct system board FRU number
before installing the board in the printer.
J4

J3
1

1

FRU label

1
1
1
1
1
J15 J19
J9 J11 J14

1

1

1

J10

J7

J5

J2

50
99
49 100

J13

J8

J22
1

1

+42V
+5V
HEAT

J16

1
J31

1 J28

J29
1

J27

OPTION CARD

+24V
1+3 3V
GND

1 1
J24 1 J26 J32

FRU No
XXXXXX

1
J34

OPTION CARD

Replace the system board.

950 Error after replacing interconnect board

1

FRU

Action

Interconnect board

Note: Before replacing the interconnect board, make absolutely sure
you have the correct FRU number for the interconnect board that
should go into your printer.
Warning: Any time the interconnect board assembly is replaced, the
Configuration ID must be reset in NVRAM on the interconnect board.
Go to“Setting configuration ID” on page 3-18.
Replace the interconnect board.
If this does not clear the message, contact the next level of support or
Lexmark.

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Charge roll service check
Service tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 in.) apart, or spots on the
page can be caused by a damaged or contaminated charge roll.
Service tip: Make sure the right charge roll arm bushing is correctly installed and operates correctly.
To remove the charge roll:

1. Wrap a piece of plain white paper around the charge roll to prevent contamination or damage.
2. Carefully remove the roll by pressing outward and to the right on the charge roll link arm and
remove the charge roll from the right side charge roll bearing.

3. Remove the charge roll from the left side charge roll bearing and remove the roll from the
printer. Leave the paper wrapped around the charge roll until it is reinstalled.
FRU

Action

1

Charge roll assembly

Check the charge roll for correct installation, toner buildup, marks,
cuts, or other signs of contamination or damage. Replace as
necessary.

2

Left side charge roll link

Check the left side charge roll link assembly for correct assembly
operation. Check for damage to the arm or bearing assembly.

3

Right side charge roll link
Right charge roll bushing

Check the right side charge roll link assembly for correct assembly
operation. If incorrect, replace the charge roll link assembly with the
charge roll link assembly kit. If correct, check the right charge roll link
assembly bearing for signs of wear or contamination. Excessive
contamination could cause intermittent charging of the charge roll. If
incorrect, replace the link assembly. Check for continuity of the right
link assembly from the bearing to the charge roll high voltage contact
on the right side frame. If incorrect, replace the link assembly.
Make sure the charge roll bushing is installed and operating correctly.
Note: The screw that attaches the charge roll lead to the contact
must be secure.

Diagnostic information

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Cover closed switch/cable service check
FRU

Action

1

Toner cartridge

Make sure the toner cartridge is correctly installed and that the right
and left cartridge tracks are not loose or broken. Make sure the cover
closed switch activation tab on the toner cartridge is not broken and
that the tab correctly activates the cover closed switch spring.

2

Cover closed switch/cable
assembly

Check the cover closed switch for proper mechanical operation. If
incorrect, repair as necessary. Disconnect the cover closed switch
cable from J3 at the system board and measure the voltage at J3-3. It
measures approximately +5 V dc. If the voltage is incorrect, replace
the system board. If the voltage is correct, check the voltage at J3-1.
If the voltage measures greater than +1.0 V dc, replace the system
board. If the voltage is correct, check the continuity between J3-1 and
J3-3 on the cable. If no change in continuity occurs as the switch is
activated, replace the cover open switch/cable assembly. If the
continuity changes as the switch is activated, replace the system
board.

Cover closed switch table
J3
Pin number

Switch status
Cover open

Cover closed

Pin 1-3

Open

Closed

Pin 1-2

Closed

Open

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Dead machine service check
A dead machine is a condition where the display is blank, the LED on the operator panel is off, no
fans turn, no motors turn, and the fuser lamp does not come on.
If a high-capacity input tray is installed, remove the option and check the base printer for correct
operation. If the base printer operates correctly, go to “High-capacity feeder input tray service
check” on page 2-56. If the base printer continues to not operate correctly, remove any other
attached paper handling options.
Warning: Observe all necessary ESD precautions when removing and handling the system board
or any installed option cards or assemblies. See “Handling ESD-sensitive parts” on
page 4-1.
CAUTION: When you see this symbol, there is a danger from hazardous voltage in the
area of the printer where you are working. Unplug the printer before you begin, or use
caution if the printer must receive power in order to perform the task.
Remove any input and output paper handling options from the printer.
Action

1

Line voltage

Check the AC line voltage. If the line voltage is incorrect, inform the
customer.

2

AC line cord

Unplug the line cord from the wall outlet and check the line cord for
damage, such as, a damaged plug, or cut or damaged cord. If
incorrect, replace the cord. If incorrect, check the continuity of the line
cord and replace if necessary. If the cord is correct, go to step 3.

3

+5 V dc test point on the
system board

Check for approximately +5 V dc at the +5 V test point on the system
board.
Note: Use care not to short adjacent voltage test points.

+24V
+3.3V
GND

1

+42V
+5V
HEAT

J24

FRU

If the voltage is correct, replace the system board assembly. If the
voltage is incorrect, go to step 4.

4

System board and
interconnect board

Check the system board is firmly seated in connector J7 on the
interconnect board. If it is not seated correctly, reseat and recheck
the voltage at the +5 V dc test point on the system board.
If test point does not measure +5 V dc, go to step 5.

Diagnostic information

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4060-xxx

Action

LVPS

Unplug the AC line cord from the LVPS and disconnect the
interconnect card cable on the LVPS. Reconnect the AC line cord and
measure the voltage on CN2-1 on the LVPS. The voltage should
measure approximately +5 V dc.

18

10

9

1

CN2

5

FRU

If the voltage is correct, go to step 6. If the voltage is incorrect, go to
step 10.

6

Interconnect board

Unplug the AC line cord from the LVPS and reconnect the
interconnect board cable to CN2 on the LVPS. Reconnect the AC line
cord, turn the machine on and measure the voltage at the +5 V test
point on the interconnect board. The voltage should read
approximately +5 V dc.

Test
Points

J4
+24V
+5V

J5
F1
F2

If correct, replace the following FRUs in the order shown:
• System board
• Interconnect board
If the voltage is incorrect, go to step 7.

7

Interconnect board

Unplug the AC line cord from the LVPS, remove the inner shield and
system board assembly from the interconnect board.
Note: The inner shield with system board attached can be moved far
enough away from the printer to access the interconnect board
voltage test points.
Measure the voltage at the +5 V test point on the interconnect board.
The voltage should measure +5 V dc. If correct, go to step 11. If
incorrect, go to step 8.

8

Communications card

Turn the printer off and remove the communications card. Check the
voltage at the 5 V test point on the interconnect board.
If the voltage is correct, replace the communication card assembly. If
the voltage is incorrect, go to step 9.

9

Features or option installed
on the interconnect board
assembly

Warning: Observe all the ESD precautions and turn the printer off
before any feature or option cards are removed or replaced.
Remove one option/feature at a time to help isolate the failing part.
Replace the faulty part.

LVPS fuse F1 (primary
power)

Unplug the AC line cord, remove the LVPS from the printer, and
check the continuity of fuse F1. See “Low voltage power supply
removal” on page 4-42.
If continuity is correct, replace the LVPS assembly.
If continuity is incorrect, replace fuse F1 and measure the voltage at
CN2-1. If the voltage is correct, reconnect the interconnect board
cable, reinstall the system board, and recheck the printer for a dead
machine condition. If the printer is still inoperative, go to step 11.
If the voltage is incorrect, replace the LVPS assembly.

10

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11

FRU

Action

Loads connected to the
system board

Turn the printer off and disconnect each cable connected to the
system board and each option installed on the system board until the
problem is located.
Warning: When removing any card installed on the system board
observe all ESD precautions when handling these options.

Duplex option service check
Messages displayed when a 23x Duplex Paper Jam displays.
23x Paper Jam

Leave Job

Check Duplex

in Finisher

Primary message

Secondary message

If sheets have been accumulated to be stapled or offset when the jam is detected, the printer
alternately flashes the primary and secondary messages to indicate that all accumulated sheets
should not be removed during the jam clearance procedure. Obviously, if no sheets have
accumulated for stapling, then no message flashing occurs and the primary message is used.
When the secondary message is posted, if accumulated sheets are removed during jam clearance,
the printer does not reprint the removed sheets. Furthermore, after the printer resumes printing and
the print job is completed, the portion of the job printed after the jam is not stapled.

Duplex paper jams
23x jam code

Jam location

231 Rear

Media did not arrive at the duplex input sensor, but did leave the fuser exit
sensor.

232 Rear

Media did not clear the duplex input sensor, but did leave the printer fuser exit
sensor.

233 Rear

Media failed to make the duplex double feed sensor during turnaround.

234 Rear

Media did not arrive at the duplex exit sensor.

235 Front

A piece of media is over the duplex double feed sensor.

236 Front

Media did not leave the duplex exit sensor.

237 Front

A duplexed sheet did not reach the printer input sensor.

238 General Error

A piece of media is over the duplex sensors during a reset.

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Duplex does not recognize that the option is installed, or other options below
the duplex are installed

1

FRU

Action

Autoconnect cables/
connections

Check the top and bottom autoconnect connectors for signs of
damage. If damaged, replace the duplex option. If not damaged,
check the cables are correctly connected to the duplex system board
at J9, J10, J11, and J12. If no problem is found, replace the duplex
option.

Note: Before proceeding with the following service checks, verify the media used in the duplex
option meets specification and is not dog-eared or damaged in any way. See “Media
specifications” on page 1-8.

231 Jam displays on the operator panel
FRU

Action

1

Fuser exit sensor

Check the sheet of media is leaving the exit sensor in the fuser and
feeding properly into the duplex option. Check the duplex link for
correct operation and any signs of damage. If the problem is prior to
the duplex input sensor and in the base machine, repair as
necessary. If the jam occurs in the duplex option prior to the duplex
input sensor, go to step 2.

2

Duplex input sensor

If the paper does not reach the duplex input sensor, make sure the
sensor is connected to the duplex system board. If correct, check for
any paper or other objects that might cause a paper jam. If none are
found, replace the duplex option assembly.

232 Jam displays on the operator panel

1

FRU

Action

Duplex input sensor

If the paper reaches the duplex input sensor, but does not clear the
sensor, make sure the sensor is connected to the duplex system
board. If connected correctly, check for correct operation of the
sensor. If a problem is found and cannot be corrected, replace the
duplex option assembly. If no problem is found, check for a piece of
paper or other object in the paper path that might cause a paper jam
over the input sensor. If no problem is found, replace the duplex
option assembly.

233 Jam displayed on operator panel

1

FRU

Action

Duplex double feed sensor

If a sheet of paper fails to reach the double feed sensor during
turnaround, check for any signs of paper or other objects that might
cause the paper to jam. If no problem is found, replace the duplex
option assembly.

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Envelope feeder service check
Service tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If
any other options are installed make sure they are operating normally. If only the envelope feeder is
failing to operate correctly, continue with this service check, otherwise verify the interconnect card is
functioning properly.
Service tip: The envelope feeder receives its +5 V dc operating voltage from the +24 V dc bulk at J17. If +24 V dc is not present at J1-7, tray 1 is the only tray that is recognized.
Note: If a 260 Paper Jam Check Envelope message displays, check the “Sub error codes for 9xx
and 2xx error codes” on page 2-5.

Printer does not recognize the envelope feeder as an attached input option.
FRU

Action

1

Envelope feeder

Make sure the envelope feeder is correctly installed and mated to the
autoconnect at the front of the printer.

2

Front autoconnect on
printer

Check the connector for signs of damage to the connector or
contacts. If you find damage, replace the damaged cable/connector
assembly. Remove the envelope feeder and check the voltages at the
autoconnect on the front of the printer. If incorrect, check the
interconnect board. If correct, reinstall the envelope feeder and
continue with step 3.

3

Autoconnect on the
envelope feeder

Check for damage to the connector or contacts. If you find damage,
replace the damaged cable/connector assembly. Disconnect the
autoconnect cable at J1 on the envelope system board and measure
the following voltages:
• J1-3 measures +5 V dc
• J1-5 measures +5 V dc
• J1-7 measures +24 V dc
If any of the voltages are incorrect, replace the autoconnect cable/
connector. If the voltages are correct, replace the envelope system
board.

Operator panel displays 260 Paper Jam immediately when envelope feed is
requested–POST incomplete.

1

FRU

Action

Pass thru sensor

Check for any debris or pieces of envelope over the pass thru sensor.
Check for correct installation of the pass thru sensor flag. Make sure
the sensor cable is attached to the envelope system board. Perform
an envelope feeder sensor test to check both the sensor and sensor
flag.
Note: It may be necessary to use a small tool to actuate the sensor
flag because it is located under the front cover. Be careful not to
damage the flag.
If the test fails, check the flag for damage or binds. If incorrect,
replace the flag. If the flag is operating correctly, check the voltage at
J3-3. The voltage measures approximately +5 V dc. If incorrect,
replace the envelope system board. If correct, check the voltage at
J3-2. The voltage changes from 0 to +5 V dc when the flag is moved
in and out of the sensor. If incorrect, replace the sensor assembly. If
this does not fix the problem, replace the envelope system board.

Diagnostic information

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Operator panel displays 260 Paper Jam after attempted feed but before
envelopes are put in the hopper OR the operator panel continues to display Load
Envelopes after envelopes are placed in the hopper.
Service tip: The kick rolls rotate during the attempted feed cycles.
FRU

Action

1

Envelope out hopper
sensor flag

Check the envelope out sensor flag for damage, correct installation
and operation. If incorrect, repair or replace the flag.

2

Envelope out hopper input
sensor

Make sure the sensor is installed correctly and the sensor cable is
properly connected to the envelope system board. If correct, perform
the Envelope Feed Sensor Test to check both the sensor and flag. If
the test fails, remove any envelopes in the hopper, turn the printer off
and disconnect J3 from the system board. Turn the printer on and
check the voltage at J3-3 on the system board. The voltage
measures approximately +5 V dc. If incorrect, replace the envelope
system board. If correct, replace the input sensor assembly.

990 Service Error, envelopes fail to feed from the hopper.
FRU

Action

1

DC feed motor assembly

Check the motor and motor cable for loose wires or poor
connections. Make sure the motor cable is connected to the envelope
system board.

2

Envelope feeder system
board

Check the voltage on J4-1. The voltage measures approximately
+24 V dc. If incorrect, replace the envelope system board. If correct,
measure the voltage at J4-6. The voltage measures approximately
+5 V dc. If incorrect, disconnect J4 and measure the voltage again. If
incorrect, replace the envelope feeder system board. If correct,
replace the DC motor assembly.

260 Paper Jam displays, unable to clear and envelopes fail to feed from the
hopper–Kick rolls are not rotating.
FRU

Action

1

Main drive belt

Check the belt for correct installation and for signs of damage.
Replace as necessary.

2

Gears

Check all the gears for correct installation and for signs of damage.
Repair or replace parts as necessary.

3

Clutch latch assembly

Check the clutch latch assembly to make sure it moves freely.

4

Master cam gear master/
kick gear

Check the master cam gear and master/kick gear to make sure they
rotate together. If not, then the tenons on the master kick gear may
be sheared off. If incorrect, replace the master kick gear.

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260 Paper Jam displays, unable to clear and envelopes fail to feed from the
hopper. Kick rolls are rotating.
Check the deflector gap adjustment before continuing this service check.
FRU

Action

1

Deflector gap adjustment

Check the deflector gap adjustment. The adjustment may be too
narrow.

2

Weight assembly

Check the weight assembly to make sure it moves up and down
freely without any binds. Make sure the weight assembly rests on all
the rear kick rollers when the hopper is empty. Replace the weight
assembly if it is damaged or does not operate properly.

3

Envelope edge guide

Check the envelope edge guide to make sure it is not warped or set
too close to the envelopes in the hopper. Replace the edge guide if it
is damaged or does not operate properly.

260 Paper Jam displays, envelope stops in feeder paper path.
FRU

Action

1

Kick rolls/feed rolls/drive
rolls

Check all the rolls for oil, grease, or other contamination. If you find a
problem, clean the rolls. If this does not correct the problem, replace
the envelope feeder.

2

Deflector gap adjustment

Check the deflector gap adjustment. The adjustment may be too
narrow.

Envelope feeder multifeeds or may not display a 260 Paper Jam message.
FRU

Action

1

Envelopes

Check the envelopes being used in the feeder. Check for signs of the
envelopes being stuck together or signs of glue. Make sure the flaps
are not interleaved.

2

Deflector

Check the deflector gap adjustment. The adjustment may be too
wide.

3

Restraint roll bias spring

Check for a missing, broken or incorrectly installed restraint roll bias
spring. If incorrect, reinstall or replace the spring.

260 Paper Jam displays, an envelope stopped in the paper path of the feeder
and an envelope also stopped in the base printer paper path.

1

FRU

Action

Latch lever

Make sure the tip of the latch lever is centered in the opening in the
floor of the paper path. The latch lever may not be detented on the
latch.

Diagnostic information

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Fuser service checks
Cold fuser service check
Error codes 920, 921, and 922 may display for a cold fuser failure. A 920 error caused by low line
voltage can sometimes be cleared by turning the machine off and then on again. A 925 service error
indicates the wrong fuser lamp is installed. Be sure the correct type of fuser lamp is installed.
CAUTION: There is a danger from hazardous voltage in the area of the printer where you
are working. Unplug the printer before you begin, or use caution if the printer must receive
power in order to perform the task.
If the correct lamp is installed and a 925 error remains, the problem may be due to the following:

• The fuser may have reached standby temperature too quickly.
• The line voltage may be above the maximum rating for the printer.
Note: A 920, 921 or 922 fuser error may be caused by an incorrectly mounted thermistor.
Service tip: Set the Fuser Temperature to NORMAL before starting this service check.
FRU

Action

1

Fuser lamp (incorrect lamp/
925 Service Error)

Install the correct voltage and wattage lamp or fuser assembly. See
“Fuser assembly removal” on page 4-23.
If the correct fuser lamp is installed and the 925 error remains, the
fuser may have reached standby temperature too quickly. Check that
the line voltage is not exceeding the maximum rating for the printer.

2

Fuser lamp
fuser top cover assembly

Observe the lamp through the left side frame. If the lamp does not
come on, do the following:
• Remove the redrive assembly.
• Remove the fuser assembly, disconnect the LVPS to fuser AC
cable from the fuser assembly, and remove the fuser. See “Fuser
assembly removal” on page 4-23.
• Verify that the lamp is installed correctly. If correct, check the
continuity of the fuser top cover assembly by verifying the lamp
contacts on the right contact assembly. If incorrect, check
continuity of the fuser lamp. If incorrect, replace the lamp. If
correct, replace the fuser top cover assembly.

3

LVPS
LVPS to fuser AC cable

CAUTION: When taking measurements for AC power, observe all
safety precautions.
Measure the AC line voltage between the two connectors on the
fuser end of the LVPS to fuser AC cable. If the voltage is incorrect,
turn the power off, and remove the LVPS. Measure the AC line
voltage between pins CN1-1 and CN1-3 on the board. If correct,
check the continuity of the LVPS to fuser AC cable. If incorrect,
replace the cable.
If the AC line voltage at CN1 is incorrect, check fuse F2. If the fuse is
blown, replace the fuse. If the fuse is not blown, replace the LVPS
assembly.

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4

FRU

Action

Fuser top cover assembly
(assembly includes
thermistor and thermal
fuses)

Disconnect the thermistor cable from the fuser control board at J6.

1

1

J2
J4
1

1
J1

J6

J5
1

Resistance:
• HOT J2-1—J2-2 <10K ohms
• COLD approximately 450K ohms
If the resistance is incorrect, replace the fuser top cover assembly. If
the resistance is correct, check each pin of J6 to ground. If there is
continuity, replace the fuser cover assembly. See “Fuser cover
removal” on page 4-25.

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Hot fuser service check
Error Code 923: Indicates the fuser is too hot during printing or when the printer is idle.
Error code 924: Indicates an open circuit has been detected in the fuser thermistor circuit.
Note: Check the fuser sub error codes to help diagnose between a 923 and 924 error.
CAUTION: The fuser may be hot, use caution before removing or servicing.
CAUTION: There is a danger from hazardous voltage in the area of the printer where you
are working. Unplug the printer before you begin, or use caution if the printer must receive
power in order to perform the task.
FRU

Action

1

Fuser cover assembly
(assembly includes
thermistor and thermal
fuses)

Check for damage to the thermistor assembly. If damage is found,
replace the fuser top cover assembly. If no damage is found, check
the resistance of the thermistor between pins J6-1 and J6-2 on the
cable.
• HOT < 10K ohms
• COLD = approximately 450K ohms
If the resistance is incorrect, replace the fuser top cover assembly. If
the resistance is correct, check each pin of J6 to ground. If there is
continuity, replace the fuser cover assembly. See “Fuser cover
removal” on page 4-25.

2

Fuser assembly

Check for continuity between J6-1 and J1-2 and between J6-2 and
J1-3. If incorrect, replace the fuser assembly. If correct, go to step 3.

3

Fuser to system board DC
cable

Check the continuity of the cable. If incorrect, replace the cable. If
correct, go to step 4.

4

System board

Measure the voltage on J14-3 on the system board. The voltage
should change from approximately +2.5 V dc with the thermistor cold
to approximately +1.6 V dc when the thermistor is hot. If incorrect,
replace the system board. If correct, go to step 5.

5

Fuser hot roll
Fuser hot roll bearings
Fuser backup roll bearings
Fuser backup roll
Fuser mechanical parts

Examine the fuser assembly for signs of overheating or damage.
Check the hot roll and backup roll for signs of excessive toner, label
glue, labels, or other contaminants. If problems are found, replace the
fuser assembly.

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Fuser solenoid service check
CAUTION: There is a danger from hazardous voltage in the area of the printer where you
are working. Unplug the printer before you begin, or use caution if the printer must receive
power in order to perform the task.
Service tip: Try changing the envelope enhance level setting. A different setting may correct the
problem.
Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment
section “Fuser solenoid adjustment” on page 4-2.

1

FRU

Action

Fuser envelope conditioner
solenoid

Observe the operation of the fuser solenoid by removing the redrive
assembly. Check for proper mechanical operation of the solenoid and
associated hardware, link, and so on. If correct, check the resistance
of the solenoid between J4-1 and J4-2 on the fuser control board.

1

1

J2
J4
1

1
J1

J6

J5
1

The resistance measures between 5 ohms and 10 ohms. If incorrect,
replace the fuser assembly. If correct, go to step 2.

2

System board

Measure the voltage at the +42 V dc test point on the system board.
The voltage should measure approximately +42 V dc. If incorrect, go
to step 3. If incorrect, go to step 4.

3

LVPS

Measure the voltage at CN2-18 on the LVPS. The voltage should
measure approximately +42 V dc. If incorrect, replace the LVPS
assembly. If correct, replace the system board. If this does not fix the
problem, replace the interconnect board assembly.

4

Fuser board to system
board cable

Make sure the cable is connected properly to the system board and
fuser control board. Reconnect the cable, if necessary. If the cable is
connected correctly, go to step 5.

5

Fuser assembly

If no problems were found in steps 1 through 4, replace the fuser
assembly. See “Fuser assembly removal” on page 4-23.

Diagnostic information

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High-capacity feeder input tray service check
Note: Voltage measurements in the high-capacity feeder input tray service checks must be made
with the high-capacity feeder attached to the base printer to obtain accurate results.
Service tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper
guides are in the correct locations for the size of paper installed in the high-capacity feeder tray.
Service tip: Check the other paper sources to be sure they are operating correctly.

The base printer indicates a dead machine condition when the high-capacity
input tray is installed.

1

FRU

Action

AC line cord
AC jumper (HCIT to printer)
AC input and output
receptacles
AC wiring harness

If the base printer works normally using the AC line cord from the AC
wall outlet and does not work when using the AC jumper from the
HCIT, check the AC jumper cord. If defective, replace the cord. If not
defective, check the AC input and output receptacles and wiring
harness in the HCIT. Repair or replace the receptacles or AC wiring
harness as required.
Note: Make sure the ground wire is installed correctly from the AC
wiring harness to the frame of the HCIT and the nut and lock washer
are tightened.

The base printer does not recognize that the high-capacity input tray is
installed.
FRU

Action

1

high-capacity feeder
autoconnect mechanical
check

Check the high-capacity feeder input tray to make sure it is mounted
correctly and is not pushed down into the frame assembly or
damaged. Be sure the high-capacity feeder input tray autoconnect is
properly connected to the high-capacity feeder tray option board
assembly.

2

Base printer or option
mounted above

Check the option or base printer autoconnect for signs of damage.
Repair the high-capacity option autoconnect as necessary.

3

LVPS
Option system board

Check the voltages at J11-2 and J11-4. The voltage measures
+24 V dc, If the voltage is correct, replace the high-capacity system
board assembly. If the voltage is incorrect, check the continuity of the
AC input cable to the LVPS. If correct, replace the LVPS assembly. If
incorrect, replace the AC cable to the input of the LVPS.

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4

FRU

Action

High-capacity feeder option
control board

Check the voltage on J8-1 (green). The voltage measures +24 V dc.
If incorrect, check the autoconnect system for any problems.
+24 V dc must come from the base printer through the autoconnect
system to the high-capacity input for the high-capacity feeder to be
recognized. If the voltage is correct, check the voltages at J11-3(red)
and J11-4(red). The voltages measure +24 V dc. If correct, replace
the high-capacity feeder option system board. If incorrect, disconnect
J8 from the system board and measure the voltages again. If
incorrect, check the LVPS cable and the AC internal wiring from the
input appliance receptacle. If incorrect, replace as necessary. If
correct, replace the LVPS. If the voltages are correct, check the
stepper motor for shorts from the motor housing to each pin on the
motor connector. If you find a short between any pin and the motor
housing, replace the motor assembly. If no shorts are found, replace
the high-capacity feeder option control board.
Check the voltage at J9-1 (light blue). The voltage measures
approximately +24 V dc. If incorrect, disconnect the cable at J9 and
check the voltage again. If the voltage continues to be incorrect,
replace the high-capacity feeder option system board. If the voltage
measures correctly, check the cable. If the cable is damaged, replace
as necessary. If no problem is found with the cable, replace the highcapacity feeder option control board.

24x Paper Jam displays, paper jammed over the Pass Thru Sensor.
Where x=the printer displays the value of x for the paper tray where the error occurs. For example:
242 is a Paper Jam Tray 2
FRU

Action

1

Pass thru sensor and flag
assembly

The tray x option system board did not detect a piece of paper
actuating the pass thru sensor. Remove any jammed sheets of paper
from the printer and check the pass thru sensor and flag for proper
operation by running the appropriate Tray Sensor Test from the
diagnostics menu. If the test fails, check the sensor for correct
installation and the flag for proper operation. Also check the sensor
cable to make sure it is correctly connected to the option system
board. If incorrect, replace the tray x option pass thru sensor
assembly.

2

Power takeoff shaft and
spring, bevel gear, feed roll
gear, drive roll assembly,
wear plate, drive shaft
bearings, and skewed
backup roller

Check these parts for signs of broken or damaged parts,
contamination on the drive rollers or wear plate and wear or damage
to the drive shaft bearings. Check the drive roll assembly and skewed
backup roller for wear, slick spots, material buildup, and oil or grease
on the rollers. Also check for proper operation of the paper aligning
assembly. Repair or replace parts as necessary.

Tray x Paper Low displays when tray x is full or has adequate paper in the tray.

1

FRU

Action

Paper low switch
Paper low switch cable
High-capacity feeder Input
system board

Run the sensor diagnostics for tray x (x=the number that represents
the high-capacity input tray). If the test fails, disconnect the paper low
switch cable from J3 on the high-capacity system board. Short pins 1
and 2 together while observing the sensor test on the display. If the
display does not change, replace the high-capacity feeder system
board. If the display changes check the continuity of the switch. If
incorrect, replace the switch. If correct, replace the switch cable.

Diagnostic information

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Tray x empty displays when there is paper in the high-capacity feeder input
tray.
FRU

Action

1

Paper out sensor flag

2

Paper out sensor
(on option system board)

Check the paper out sensor flag for correct operation and installation.
If correct, replace the high-capacity feeder system board. (The paper
out sensor is mounted on the high-capacity feeder system board.)

The elevator tray fails to stop at the correct position and continues to drive
into the bottom frame.
FRU

Action

1

Lower limit switch
Lower limit switch cable

Check continuity of the lower limit switch. If incorrect, replace the
switch. If correct, check the switch cable. If incorrect, replace the
cable. If correct, replace the high-capacity feeder option control
board.

2

High-capacity feeder
control board

Disconnect the lower limit switch cable and check the voltage at J2-1
(orange). The voltage measures approximately +5 V dc. If incorrect,
replace the high-capacity feeder option control board.

The elevator tray down button does not operate. The tray moves to the upper
position.
Service tip: Open the high-capacity feeder front door and check the black rubber bumper attached to
the door switch spring. Be sure the rubber button is centered and not touching the sides of the hole or
the switch will not function properly.

1

FRU

Action

Lower limit switch
Lower limit switch cable
High-capacity feeder
control board

Check the lower limit switch to make sure it is not closed (normally
open). If incorrect, replace the switch. Check the lower limit switch
cable for a short between pins 1 and 2. If incorrect, replace the cable.
If correct, replace the high-capacity feeder control board.

Paper from the high-capacity feeder input tray does not reach the pass thru
sensor.
Service tip: Be sure the paper in tray is within specifications.
FRU

Action

1

Autocompensator
assembly

Check the autocompensator pick arm rollers for sign of glazing, toner
or other buildup. Replace as necessary.

2

Wear strips

Check the wear strips for glazing or contamination. Replace as
required. It is advisable to replace all four wear strips at the same
time.

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The elevator tray does not move up or down. The printer recognizes that the
option is installed.

1

FRU

Action

DC drive motor highcapacity feeder option
system board

Be sure the motor cable is correctly installed at J1 on the board.
Check the cables, damaged or loose wires. Disconnect the motor.
Check for a short between each pin and the motor housing. If a
problem is found, replace the motor assembly. If no problem is found,
measure the resistance between the following pins on the motor
cable connector:
Pins 1 (brown) and pin 2 (Yellow)
The resistance measures between approximately 7.5 and 10.5 ohms.
If incorrect, replace the motor assembly. If correct, replace the highcapacity feeder option system board.

The elevator moves in one direction only.

1

FRU

Action

DC drive motor assembly
high-capacity feeder
system board

Check the voltages at J1 on the high-capacity system board. The
voltages measure approximately as follows:
Pin

Color

Voltage

Static (motor not running)
J1-1

Brown

0 V dc

J1-2

Yellow

0 V dc

Motor running forward
J1-1

Brown

0 V dc

J1-2

Yellow

+24 V dc

Motor running in reverse
J1-1

Brown

+24 V dc

J1-2

Yellow

0 V dc

If any of the voltages are incorrect, disconnect the motor and
measure the resistance between J-1 and J-2. The resistance
measures between 7.5 and 10.5 ohms. If incorrect, replace the
motor. If correct, replace the system board.

Diagnostic information

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Paper size switch not selecting paper size that is selected.

1

FRU

Action

Paper size switch
High-capacity feeder option
control board

Check for continuity between the common pin (J5-1) and the pin of
the paper size selected.
Pin

Color

J5-1

Black

Paper size
Common lead

J5-2

Blue

B5

J5-3

Green

Executive

J5-4

Yellow

A4

J5-5

Orange

Letter

J5-6

Red

Legal

J5-7

Brown

A5

If any position does not measure continuity when selected, replace
the paper size switch assembly. If the switch assembly is operating
correctly, replace the high-capacity feeder option control board.

24x Paper Jam Check Tray x displays when tray x is empty. Tray x does not
display.
FRU

Action

1

High-capacity feeder option
control board

Check the voltages on the board at J4-1(red) and J4-3 (blue). The
voltages measure approximately +5 V dc. If incorrect, disconnect J4
from the board and measure the voltages again. If incorrect, replace
the high-capacity feeder option control board.

2

Elevator top optical sensor
cable
Elevator top optical sensor

Check the continuity of the sensor cable. If incorrect, replace the
cable. If correct, replace the top optical sensor assembly.

Tray x Empty displays. Tray does not respond to loading paper. No response
from the front door switch.
FRU

Action

1

High-capacity feeder option
control board

Check the voltage on the board at J4-2 (green). The voltage
measures approximately +5 V dc. If incorrect, disconnect the cable at
J4 and check the voltage again. If incorrect, replace the high-capacity
feeder option control board.

2

Elevator top optical sensor
cable
Elevator top optical sensor

Check the continuity of the sensor cable. If incorrect, replace the
cable. If correct, replace the top optical sensor assembly.

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Tray x Paper Low displays when the high-capacity feeder input tray is full or
has adequate paper in the tray.

1

FRU

Action

Paper low switch
Paper low switch cable
High-capacity feeder option
control board

Run the sensor diagnostics for tray x (x=the number that represents
the high-capacity input tray).
If the test fails, check the voltage at J3-1 (gray). The voltage
measures approximately +24 V dc. If incorrect, disconnect the paper
low switch cable from J3 and measure the voltage again on J3-1. If
incorrect, replace the high-capacity feeder option control board. If
correct, check the cable for a short between pins 1 and 2 on the
cable. If incorrect, replace the cable. If correct, check the switch for a
bent or deformed actuator lever or defective switch. If incorrect,
replace the switch.

Excessive noise or vibration
FRU

Action

1

DC motor assembly

Make sure all the motor plate mounting screws are tight.

2

Idler pulley
DC motor assembly

Make sure the idler pulley is not binding on the pulley shaft. Check
the pulley for wear. Check the idler pulley shaft on the motor
mounting plate for damage or contamination.

3

Drive pulley

Check the drive pulley for wear, binds or damage to the pulley or
pulley shaft. Make sure the pulley turns freely on the pulley shaft.

4

Motor drive belt
tray drive belt

Check the DC motor drive belt for damage. Make sure the belt is
tracking correctly on the drive pulley, idler pulley, and motor pulley.
Check the tray drive belt for damage. Make sure the belt is tracking
correctly on the lower section of the drive pulley and lead screw
pulleys.

Diagnostic information

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High-capacity output stacker service check
Service tip: The majority of the mechanical components can be observed during operation by
removing the left, right, and front covers. The high-capacity output stacker option functions without
the covers installed.
Determine which paper path stacker assembly is not functioning properly.
Make sure the option(s) are installed correctly and the machine is configured correctly before
attempting to service the high-capacity output stacker option.
See “High-Capacity Output Stacker Board” on page 5-14 to identify the correct jumper locations
at J6 for the upper and lower units.

Problems with excessive static electricity buildup.

1

FRU

Action

Front Cover Assembly

Check the front cover assembly to make sure the ESD brush ground
lead is firmly attached to the high-capacity option. Also check to
make sure the ESD brush is not loose or damaged.

The printer does not recognize one or more output options as installed.
Service tip: If more than a single output option is installed, check each one to see if the printer
recognizes any single option as installed. If the printer recognizes any of the output options, the base
printer autoconnect system is operating correctly. The problem is in the unrecognized option.
Continue with this service check or go to the service check for the failing output option.
FRU

Action

1

High-capacity stacker
feeder

Check the autoconnects, cables, and connectors of the option for any
signs of loose or damaged parts.

2

High-capacity output
stacker/mechanical linkage
assembly

Remove the left and right side covers and check all four
autoconnects for damage, especially the connector pins. Remove the
output option and check the voltages on the standard output bin
autoconnect located on the top left rear of the printer. Go to
“Autoconnect” on page 5-1. If the voltages are correct, reinstall the
output option and note the positions of the toroids on the autoconnect
cables on the upper and lower assemblies, and check the voltages on
the autoconnects. If all voltages are correct and the lower assembly
is failing, replace the lower control board. If the upper assembly is
failing, replace the upper control board. If the voltages are incorrect,
replace the upper or lower failing mechanical linkage assembly.

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202 Paper Jam Open Rear Door displays and a sheet of paper is jammed prior
to the pass thru sensor flag or 202 Paper Jam Open Rear Door displays, a
sheet of paper feeds out to the standard bin even though bin x is selected and
paper exits half way out of the redrive assembly.
Service tip: For this type of problem check the “Base printer sub error codes” on page 2-6. They
can help isolate the problem. A 202 paper jam message can also occur prior to the high-capacity
output stacker pass thru sensors.
FRU

Action

1

Lower Pass Thru Sensor/
Flag Assembly

Check the flag for correct operation, binding, broken parts, or
interference from the sensor cable. If incorrect, repair as necessary.
If correct, check to make sure the lower pass thru sensor is correctly
connected to J3 on the lower control board. Disconnect the pass thru
sensor cable and check the voltage at J3-3. The voltage measures
approximately +5 V dc. If incorrect, check the voltage at J3-2. The
voltage measures approximately 0 V dc. If incorrect, replace the
sensor assembly. If this does not fix the problem, replace the lower
control board.

2

High-capacity output
stacker drive belt(s)
Drive pulleys
Belt idlers
Belt tension springs

Check to ensure the output stacker drive belt or the failing assembly
is correctly installed on the drive pulley and belt idler pulley. Check
the belt tension spring to make sure it is not loose or broken. Repair
as necessary.

3

Mechanical linkage/motor
assembly (upper or lower)

If the DC motor is functioning properly check the gears, clutch and
other linkage parts for correct operation and wear, broken gear teeth,
or damaged parts. If incorrect, replace the mechanical linkage
assembly/DC motor assembly.

Remove Paper - Output Bin x Full displays. You may not be able to clear the
message.

1

FRU

Action

Dual output bin sensor flag
(upper assembly)

Check the flag for correct operation, binding, broken parts, or
interference from the sensor cable. If incorrect, repair as necessary.

271 Paper Jam - Check Bin x, POST incomplete.

1

FRU

Action

Upper pass thru sensor flag
assembly
Upper control board

Check the flag for correct operation, binding, broken parts, or
interference from the sensor cable. If incorrect, repair as necessary. If
correct, make sure the lower pass thru sensor is correctly connected
to J3 on the lower control board. Disconnect the pass thru sensor
cable and check the voltage at J3-3. The voltage measures
approximately +5 V dc. If incorrect, check the voltage at J3-2. The
voltage measures approximately 0 V dc. If incorrect, replace the
sensor assembly. If this does not fix the problem, replace the lower
control board.

Diagnostic information

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Input sensor service check
Service tip: Run the Base Sensor Test. Check the input sensor for proper operation. The display
changes from open to closed as the sensor flag is manually moved in and out of the sensor.
FRU

Action

1

Input sensor flag

Check the input sensor flag for damage and proper operation. If a
problem is found, repair as necessary.

2

System board

Check for approximately +5 V dc at J22-10 on the system board. If
incorrect, replace the system board.

3

Input sensor cable

Check the continuity of the input sensor cable section of the front
wiring harness. If incorrect, replace the harness. If correct, replace
the input sensor assembly.

Input tray(s) service check
Optional 250-sheet and 500-sheet trays
Service tip: Try all the other input paper sources to make sure they are properly feeding paper.
For 990 Error Code- Service Tray x, x= displays the number of the tray that has a problem or needs
service.

1

FRU

Action

Tray x Option system board
or compensator assembly
or autoconnect cable

Check the autoconnect cables and connectors for damage. Replace
if necessary. Check the cables for continuity. If incorrect, replace the
compensator assembly cable. If the cables, connectors, and
connections are good, replace the FRUs in the following order:
• Autocompensator assembly option
• Option system board.

24x Paper Jam displays, paper jammed over the pass thru sensor.
(The printer displays the value of x for the paper tray where the error occurs. Example: 241 is a Paper
Jam Tray 1)

1

FRU

Action

Pass thru sensor and flag
assembly

The tray x option system board did not detect a piece of paper
actuating the pass thru sensor. Remove any jammed sheets of paper
from the printer and check the pass thru sensor and flag for proper
operation by running the appropriate Tray Sensor Test from the
diagnostics menu. If the test fails, check the sensor for correct
installation and the flag for proper operation. Also check the sensor
cable to make sure it is correctly connected to the option system
board. If incorrect, replace the tray x option pass thru sensor
assembly.

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2

FRU

Action

Power takeoff shaft and
spring, bevel gear, feed roll
gear, drive roll assembly,
wear plate, drive shaft
bearings, and skewed
backup roller

Check these parts for broken or damaged parts, contamination on
the drive rollers or wear plate, and wear or damage to the drive shaft
bearings. Check the drive roll assembly and skewed backup roller for
signs of wear, slick spots, material buildup, and oil or grease on the
rollers. Also check for proper operation of the paper aligning
assembly. Repair or replace parts as necessary.

Tray x Low displays when tray x is full or has adequate paper in the tray.

1

FRU

Action

Paper low sensor assembly
Paper low sensor flag tray x
option system board

Run the Tray x Sensor Test and check the sensor for proper
operation. If incorrect, check the following:
• Paper low sensor flag for smooth and correct operation.
• Paper low sensor for correct installation on the autocompensator
housing.
• Paper low sensor cable for signs of cuts, pinched wiring, or other
damage especially at connector J5 on the system board.
If no problem is found, replace the paper low sensor assembly. If this
does not correct the problem, replace the option system board.

Tray x Empty displays when Tray x has paper in the tray.
FRU

Action

1

Paper out sensor flag

2

Paper out sensor (on option
system board)

Check the paper out sensor flag for correct operation and installation.
If correct, replace the option system board. (The paper out sensor is
mounted on the system board).

Printer does not recognize Tray x is installed.

1

FRU

Action

Autoconnect cables
Tray x system board

Check the autoconnect from the printer or option above tray x. Check
for cuts, pinched wiring, or damage to the contacts in the connector.
Check the autoconnect cable(s) for correct installation at the tray x
system board. If correct, check the continuity of the autoconnect
cable(s). If correct, replace the tray x system board. If incorrect,
replace the cable.

Paper from Tray x does not reach the pass thru sensor.
Service tip: Check the media in tray x to make sure it is within specifications. Some types of labels,
foil material, and slick papers can cause misfeeds and slippage of the rollers.

1

FRU

Action

Autocompensator
assembly

Check the autocompensator pick arm rollers for any sign of glazing,
toner or other buildup. Clean or replace as necessary.

Diagnostic information

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Internal tray card/paper size sensing service check
Before proceeding, check for the correct paper size loaded in the tray and that the tray has been set
to accept the size paper loaded in the tray.

SW2
CN1
1

SW1
SW0

Paper size sensing switch chart
ITC
CN1 pin

Signal

ITC
switch

1

PSIZE2

SW1

2

Ground

Ground

3

PSIZE1

SW0

4

PSIZE3

SW2

Paper tray size selection (X is activated)
Letter

Legal

X

A4

Exec

X

B5

System
board
J34 pin

A5
X

1
2

X

X

X

X

X

3
X

4

Tray 1 not recognized as being installed. Unable to clear Tray 1 Missing
message.

1

FRU

Action

Tray 1

Check Tray 1 for damaged or broken autosize fingers. Check for
anything that would prevent the autosize fingers from activating the
paper activate springs and ITC switches.

LGL

A4

LTR
EXEC
B5
A5

2
W
S
1
W
S
0
W
S

If a problem is found, repair as necessary. If no problem is found, go
to step 2.

2

Integrated card/
autocompensator cable

Check for correct installation of the cable at J34 on the system board.
If installed correctly, go to step 3. If incorrectly installed, install and
recheck the printer.

3

System board

Check the continuity between J34-2 on the system board and
ground. It should measure approximately 0 ohms.

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The printer does not recognize the paper size selected.
FRU

Action

1

Back restraint
Side restraint
Snap-in plate
Autosize slider
Autosize finger

Check all the paper size parts for damage or broken parts. make sure
the parts operate correctly. If a problem is found, repair as necessary.
If no problem is found, go to step 2.

2

Switch activate spring

Make sure the switch activate spring is not bent or broken. Replace
the spring if damaged. If the spring is not damaged, go to step 3.

3

Internal tray card (ITC)
System board
ITC cable

Set the tray for the paper size that is not recognized and install the
tray in the printer. Select the paper size and corresponding paper
switch from table, below.
Pin

Signal

Static
tray out
(V dc)

Static with paper tray in and set to: (V dc)
Letter

Legal

A4

Exec

B5

A5

1

PSIZE2

+3.3

0

0

+3.3

+3.3

0

2

Ground

0

0

0

0

0

0

0

3

PSIZE1

+3.3

+3.3

+3.3

0

0

0

+3.3

4

PSIZE3

+3.3

0

+3.3

+3.3

0

+3.3

0

5

N/A

6

N/A

7

N/A
+3.3

+3.3

+3.3

+3.3

+3.3

+3.3

+3.3

8

+3.3

9

N/A

10

N/A

+3.3

If the voltage on J34 does not change, go to step 4. If the voltage
changes, recheck the printer. If Tray 1Missing is still displayed,
replace the system board assembly.

4

System board

Ground the appropriate pin on connector J34 on the system board.
Tray 1 Missing should not be displayed. If it is not displayed, go to
step 5. If it still displays, replace the system board assembly.

5

ITC/autocomp cable
ITC assembly

Check continuity of the ITC/Autocomp cable. If correct, replace the
ITC assembly. If incorrect, replace the ITC/autocomp cable.

Diagnostic information

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Main drive service check
Service tip: Excessive gear or main drive assembly noise is usually caused by a defective motor
assembly or system board.
Service tip: If there are equally spaced horizontal lines across the page, go to “Print quality–
evenly spaced horizontal lines or marks” on page 2-80.
Warning: Whenever the gearbox assembly is removed from the machine it must be handled very
carefully. Do not allow any of the gears to come in contact with any metal or other hard
surface to avoid gear damage. It is also very important not to let any dirt, paper, staples,
or other material come intact with the grease in the gearbox assembly.
FRU

Action

1

Main drive assembly
(excessive noise or
vibration)

Remove the controller board and run a Diagnostic Print Test in the
continuous mode. Check the main drive assembly for any excessive
noise or vibration. Determine if the noise is in the main drive, toner
cartridge, fuser, or main drive gearbox. Look for any loose or worn
parts in the developer drive assembly, main drive gearbox, or fuser.
Repair as necessary.

2

Main drive motor assembly
(excessive noise, gears
ratcheting and so on)

A service error code 936 - Transport Motor may be displayed. Check
the voltage at J24-6 on the system board. It measures approximately
+5 V dc when the motor is not running and goes to 0 V dc when the
motor is running. If incorrect, replace the system board. If this does
not fix the problem, replace the main drive motor.

3

Main drive motor cable

Check the continuity of the main drive motor cable. If incorrect,
replace the cable.

4

Motor does not turn, no
gear error code 936 or user
message 201 Paper Jam
displays.

Check the voltages at J24 on the system board.
Pin

Voltage
Static

J24-11

When main drive
motor is running
+24 V dc

J24-8

+5 V dc

0 V dc

J24-7

+5 V dc

0 V dc

J24-6

+5 V dc

+2.5 V dc

J24-5

+5 V dc

0 V dc

J24-4

+5 V dc

+5 V dc

J24-1

+5 V dc

0 V dc

If the voltage is incorrect, replace the FRUs in the following order:
• Main drive motor assembly
• System board

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Main fan service check
Check the cable connections at J7 on the system board and at the main fan assembly. The main fan
runs continuously when the printer is powered on unless the printer is in the Power Saver mode.
FRU

Action

1

Main fan

Manually spin the fan and check that it rotates freely. Check the cable
connection to the system board, J7 for correct installation.

2

Main fan to system board
cable

Check the continuity of the cable. If incorrect, replace the cable.

3

Error code 927 (fan runs)

Check the voltage at J7-1 on the system board. The voltage
measures +5 V dc (static) 0 V dc (fan running). If incorrect, replace
the main fan. If this does not fix the problem, replace the system
board.

4

Error code 927
(fan not running)

Check the voltage at J7-3 on the system board. The voltages are:
• +22 V dc to +24 V dc
(printer and fan running)
• +12 V dc to +15 V dc
(printer not running–fan running about half speed).
If incorrect, replace the system board. If this does not fix the problem,
replace the main fan.

Diagnostic information

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Operator panel service check
Operator panel buttons service check
Before continuing with this service check do the “Button Test” on page 3-8.
FRU

Action

1

Operator panel assembly

If any button fails the Button Test, replace the operator panel
assembly.

2

Operator panel assembly
(no buttons work)

If no buttons work, replace the operator panel assembly.

3

System board

Disconnect the operator panel cable from J15 on the system board
and measure the voltage at J15-5. The voltage should measure
approximately +5 V dc. If incorrect, replace the system board. If
incorrect, replace the cable. If correct, replace the operator panel
assembly.

Operator panel display service check
Service tip: The printer has detected a problem with the system board, operator panel cable or
operator panel assembly if POST does not complete and the printer emits 5 beeps and stops in a
continuous pattern until the printer is turned off. The operator panel cable is an individual cable on
some printers and a combination cable assembly with the cover switch cable on later models.
Note: If the operator panel is operating properly except for a pel or a few pels missing or broken, run
the “LCD Test” on page 3-8 from the hardware tests before continuing with this service check.
FRU

Action

1

Operator panel cable

Check for proper installation of the cable at the system board (J15)
and at the operator panel. Check the continuity of the operator panel
cable. If incorrect, replace the cable.

2

Operator panel display
blank, 5 beeps, LED off

Check for correct installation of the operator panel cable at J15 on
the system board. If incorrect, reinstall the cable properly. If correct,
measure the voltage at J15-2 on the system board. The voltage
should measure approximately +5 V dc. If incorrect, replace the
system board. If correct, check continuity of the operator panel cable.
If the continuity is incorrect, replace the cable. If the continuity is
correct, replace the operator panel assembly.

3

Operator panel display
blank, 5 beeps, LED on

Check for ground between J15-4 and ground. If correct, replace the
operator panel assembly. If incorrect, replace the system board.

4

Operator panel all
diamonds, no beeps

Make sure a card is not plugged in backward. This condition causes
the printer to fail POST, displaying all diamonds on the operator panel
with no beeps.

5

Operator panel all
diamonds, 5 beeps

Check the voltage at Pin J15-1 and J15-3. The voltage measures
approximately +5 V dc. If incorrect, replace the FRUs in the following
order:
• Operator panel assembly
• System board

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Options service check
Service tip: When you have a problem with any of the options installed in the options slots on the
interconnect board, switch the non operating option to one of the other option slots to isolate the
failure.

Flash Memory Option(s)
Run a copy of the test page and check to see if the option you are checking is listed. The printer does
not recognize the option being installed if the option is not listed. Make sure the memory card is
installed correctly and is not broken or damaged. If the memory card is correctly installed and not
broken or damaged then run the “Flash Test” on page 3-3. If the test fails, replace the Flash card. If
the problem continues, replace the controller board.

DRAM Memory Option(s)
This service check is the same as the flash memory option service check with the following
exception:
Run the “SDRAM Memory Test” on page 3-9 from the menu if the SDRAM Memory card is
correctly installed and not broken or damaged. If the test fails, replace the SDRAM card. If the
problem continues, replace the controller board.

Hard Disk Option
Service tip: These printers support one hard disk option. Make sure only one hard disk option is
installed.
Make sure the fixed disk and the fixed disk board are correctly installed. Run the “Quick Disk Test”
on page 3-2 from the Device Test on the Diagnostics menu when a problem is suspected either with
the hard disk system board or with the hard disk.
Note: The Quick Disk Test is a non-destructive test and indicates Pass or Fail. If the test fails,
replace the hard disk. If a problem still exists, replace the hard disk board.
The “Disk Test/Clean” on page 3-2 is used to help restore the disk if the disk contains bad data and
is unusable. This test is divided into a cleaning and a verifying or testing section.
Warning: This can be a very lengthy test depending on the disk size. This test leaves the hard disk
unformatted. The servicer or user must reformat the disk using the Format Disk Menu
operation. This is a destructive type of test. All the data on the disk is destroyed and
should not be performed on a known good disk.

Error Code 976 - Network Card x (x=Network card 1, 2, or 3)
A 976 error code indicates an unrecoverable software error in network card x. Verify that network
card x is correctly installed in the socket on the interconnect board and is properly grounded. If you
find no problem, contact your next level of support before replacing the network card.

Error Code 977 - Network Card x
A 977 error displays when the RIP software detects that a network card is installed in slot x on the
interconnect board but cannot establish communications with the network card.

Diagnostic information

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Output bin sensor standard tray service check
Service tip: If the output bin standard tray fills up and the bin full sensor fails to post the Remove
Paper Standard Bin message:

1.
2.
3.
4.
5.

Enter the Diagnostics Mode.
Select Output Bin Tests.
Select Sensor Tests.
Select Standard Bin.
Check the sensor and flag for proper operation.

If you find no problem with the sensor and flag, continue with the service check.
Service tip: Be sure the flag is correctly installed. The output bin sensor is a normally closed sensor
with the sensor flag down. Therefore, unless the flag is in the up position or out of the sensor slot, a
Remove Paper Standard Bin message does not display.
FRU

Action

1

System board
Printer fails to display
Remove Paper Standard
Bin message. Output Bin
Sensor Test fails.

Check the voltage at J11-1. It measures +5 V dc when the flag is in
the sensor, and 0 V dc when the flag is out of the sensor. If the
voltage does not change, replace the sensor cable assembly. If this
does not fix the problem, replace the system board.

2

Output bin sensor flag

Make sure the correct flag is installed. Check the flag for damage or
improper operation. If incorrect, replace the flag.
Note: A broken or improper operating sensor flag causes a Remove
Paper Standard Bin message to display before POST completes and
cannot be cleared.

Output expander service check
Service tip: The majority of the mechanical components can be observed during operation by
removing the left, right, and system board covers. The output expander functions without the covers
installed.
Make sure the option is correctly installed before attempting to service the unit. No jumpers should
be installed at connector J6 on the output expander board.

Problems with excessive static electricity buildup.

1

FRU

Action

Output expander control
board cover

Check the output expander control board cover to make sure the
ESD brush ground lead is firmly attached to the output expander
frame. Also make sure the ESD brush is not loose.

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Printer does not recognize one or more output expander options as being
installed.
Service tip: If more than a single output expander option is installed, check each one to see if the
printer recognizes any single option as being installed. If the printer recognizes any of the output
expander options then the base printer autoconnect system is operating correctly and the problem is
in the unrecognized expander option.
FRU

Action

1

Output expander option

Make sure the output expander option is the only option that is not
recognized by the base printer. If the output expander is the only
option not recognized by the printer, continue with step 2. If not,
check the autoconnects of the options not recognized and the
interconnect board and cable connections.

2

Output expander assembly
mechanical linkage

Check the autoconnects for damage, especially the connector pins.
Remove the left and right side covers. Remove the front control board
cover. Check the cables at J1A, J1B, J2A and J2B on the control
board to make sure they are attached securely and correctly.
Remove the output expander and check the voltages on the output
bin autoconnect located on the top left rear of the printer. Go to
“Autoconnect - Top” on page 5-11. If the voltages are correct,
reinstall the output expander unit and check the voltages at J1A and
J1B on the connector. If correct, replace the output expander control
board. If incorrect, replace the output expander assembly mechanical
linkage.

202 Paper Jam Open Rear Door message displays. A sheet of paper is
jammed prior to the pass thru sensor flag.
202 Paper Jam Open Rear Door message displays. A sheet of paper feeds out
to the standard bin even though bin x is selected. Paper exits half way out of
the redrive.
Service tip: For this type of problem check the sub error codes. They can help isolate the problem.
202 Paper Jam messages can also occur prior to the output expander pass thru sensor.
FRU

Action

1

Output expander drive belt
drive
Pulley drive belt
Idler pulley belt tension
spring

Check to ensure the output expander drive belt is correctly installed
on the drive pulley and belt idler pulley. Check the belt tension spring
to make sure it is not loose or broken. Repair as necessary.

2

Mechanical linkage
DC motor assembly

If the DC motor is functioning properly check the gears, clutch, and
other linkage parts for correct operation and wear, broken gear teeth,
or damaged parts. If incorrect, replace the mechanical linkage/DC
motor assembly.

Diagnostic information

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Remove Paper - Output Bin x is displayed, POST incomplete, unable to clear
the message.

1

FRU

Action

Dual output bin sensor flag

Check the flag for correct operation, binding, broken parts, or
interference from the sensor cable, If incorrect, repair as necessary.

271 Paper Jam - Check Bin x, POST incomplete

1

FRU

Action

Pass thru sensor and flag
assembly
Control board

Check the sensor flag for proper operation. If correct, check to make
sure the pass thru sensor cable is correctly connected to J3 on the
control board. Disconnect the pass thru sensor cable from J3 on the
control board and check the voltage at J3-3. The voltage measures
approximately +5 V dc. If incorrect, replace the control board. If
correct, check the voltage at J3-2. The voltage measures
approximately 0 V dc. If incorrect, replace the sensor assembly. If this
does not fix the problem, replace the control board.

271 Paper jam - Check Bin x, POST complete, first sheet of paper feeds into
output bin x.
Note: Before performing the following checks, run the Output Bin X Sensor Test and check for the
failing sensor.
Sensor Test:
NF = Near Full (Upper part of sensor assembly)
F = Full (Lower part of sensor assembly)
P = Pass Thru Sensor

990 Service - Bin x

1

FRU

Action

D.C. motor
mechanical linkage
assembly

Make sure the DC motor cable connector is correctly installed at J4
on the output expander option board. If correct, disconnect J4 from
the option board and check the resistance of the motor on the cable
connector: J4-1 to J4-2 (measures between 115 and 135 ohms.) Also
check J4-1 and J4-2 to the motor case for shorts. If either the
resistance is incorrect or a short is found, replace the motor/
mechanical linkage assembly.
Note: If the DC motor is shorted, it may also be necessary to replace
the control board.

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2

FRU

Action

Output expander control
board

Disconnect the motor cable J4 and check the voltages at J4 on the
board.
Note: Use caution not to short to adjacent pins on the connector.
Pin

Status

Voltage

J4-1

(Motor Idle)

+24 V dc

J4-2

(Motor Idle)

+24 V dc

J4-5

(Motor Idle)

+5 V dc

J4-6

(Motor Idle)

+5 V dc

If any of the voltages are incorrect, replace the control board. If the
voltages are correct, replace the DC motor/mechanical linkage
assembly.

No indication that bin x is full or no indication that bin x is near full

1

FRU

Action

Dual output bin x sensor
assembly
Output expander control
board

Check for correct installation of the sensor cable at J5 on the output
expander control board. If either the Bin Full (F) or Bin Near Full (NF)
fail the sensor test then check the voltage at J5-3 and J5-4. The
voltage measures approximately +5 V dc. If the voltage is incorrect,
replace the output expander control board. If correct, replace the
sensor assembly.

Diagnostic information

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Paper feed service check
If you have a 936 Transport Motor Error go to “Main drive service check” on page 2-68.
FRU

Action

1

Alignment assembly

Check to ensure the alignment assembly is correctly attached to the
left side frame and the mounting screws are tight. Check the
alignment assembly for worn rollers, contaminated rollers, or binds.
Replace the alignment assembly if any problem is found.

2

Inner deflector

Check the inner paper deflector for correct installation. If the deflector
is bowed or not fitting correctly, replace the deflector.

Autocompensator fails to feed paper. Failures occur randomly throughout the
stack of paper.
FRU

Action

1

Pass thru sensor

Check the pass thru sensor for correct installation and operation.

2

Autocompensator
assembly

The autocompensator pick roll shaft assembly is not providing
enough torque if the pick rollers are not picking the paper correctly.
Replace the autocompensator assembly.

3

Wear strips in tray x
problem is found.

Check the wear strips for excessive wear, scratches, or rough spots.
Replace the wear strips if a problem is found.

Paper feed failures occur only near the top of the stack of paper.
The most common cause of this problem is paper curl. Remove the paper from tray x and check for
the natural curvature in the paper. Reinstall the paper in the correct manner. If the problem persists, it
may be necessary to reduce the stack height. Replace both pick rolls if the paper appears to be flat in
the tray but there is still a problem.

Failures occur mainly near the bottom of the stack of paper.
The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly
contact the paper. Also the autocompensator motor may be failing. If this problems continues,
replace the autocompensator assembly.

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Double feeding paper
Note: If double feeding paper occurs mostly from the bottom of the stack, check for missing or
damaged restraint pads in the tray.
FRU

Action

1

Paper

Paper is usually the primary cause of a double feeding paper
problem. Flex the paper before placing the paper in the tray. Edgewelded paper is the most common cause of double feeding. Loading
the paper in the tray in different locations and directions and using
rough paper and short grain paper also causes double feeding.

2

Autocompensator

Make sure the counterbalance spring is not missing, loose, or broken
at the top of the autocompensator arm assembly. If you find a
problem, replace the autocompensator assembly.

Multipurpose tray. Paper fails to feed from the multipurpose tray.
The pick roll should make one complete revolution and stop with the flat side down. If the pick
roll turns but does not pick paper, check the roll for signs of wear, oil or grease on the surface of
the pick roll or slick spots. If you find a problem, replace the pick roll assembly. Check to ensure
the media that is being fed through the multipurpose tray assembly meets recommended paper
specifications.

Parallel port service check
Run the “Parallel Wrap Test” on page 3-9.
Note: The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug
(P/N 1319128) and invoking the Parallel Diagnostic Test. This test helps isolate the printer from the
parallel cable and host. The test provides failure information on the display for approximately three
seconds. If the test indicates that a problem is detected, replace the controller board.

Diagnostic information

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Printhead service check
The printhead assembly does not contain any service replaceable parts or components. If service
error code 930 displays, the wrong printhead is installed in the printer. See “Printhead 1 (000/010)”
on page 7-10, “Printhead 2 (200/210)” on page 7-11, or “Printhead 3 (400/410)” on page 7-12.
Note: A 201 paper jam may also indicate a failing printhead. The paper may have jammed prior to or
at the input sensor. Print the error log and see if 201 or 931 errors are logged.
Service Error Code

Explanation

1

Error code 931
No first HYSNC Signal
Error Code 932
Lost HYSNC

These errors usually indicate a failure in the HYSNC signal to the
printhead. Check the continuity of the cables connected to J5 and J4
on the system board. If incorrect, replace the defective cable. The
voltage at J4-1 measures approximately +5 V dc. If incorrect, replace
the system board. The voltage at J5-7 measures approximately
+24 V dc. If incorrect, replace the system board. If correct, replace
the printhead assembly.

2

Error Code 934
Mirror motor lost lock Error
Code 935
Mirror motor unable to
reach operating speed

These error codes indicate a problem with the mirror motor circuit in
the printhead assembly or the mirror motor cable to the system board
cable or system board assembly. Check the continuity of the mirror
motor cable connected to J5 on the system board. If incorrect,
replace the cable. The voltage at J5-7 measures approximately
+24 V dc. If incorrect, replace the system board. If correct, replace
the FRUs in the following order:
• System board
• Printhead assembly

Print quality service check
Service tip: Before troubleshooting any print quality problems do the following:

•
•
•
•
•
•
•

Install another print cartridge if available before proceeding with the service checks.
Use Tray 1 to test for print quality of the base printer.
Replace the charge roll if it is damaged or contaminated.
Replace the transfer roll if it is damaged or contaminated.
Make sure the fuser assembly is installed correctly.
Verify proper paper type, texture, and weight settings for the media being used.
Test the printer using plain paper (20 lb).

Select the following menu settings as indicated. Be sure and note the original settings so you can
return the printer to the original customer printer setup.

• Print Resolution: Set to 300 dpi (print quality problems should be checked at different resolution
•
•
•
•
•

settings).
Print Darkness: Set to NORMAL.
Toner Saver: Set to OFF.
PQET: Set to OFF.
Fuser Temperature: Set to NORMAL.
Test the printer using plain paper (20 lb).

An incorrect printer driver for the installed software can cause problems. Incorrect characters could
print and the copy may not fit the page correctly.

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Measure all voltages from the connector to printer ground. All voltages measured during the print
cycle are measured with the controller board removed while running the print test.

Print quality–all black page
Service tip: An all black page is generally caused by a problem in the high voltage system or an
incorrect high voltage in the printing process resulting in toner development on the entire
photoconductor drum.
FRU

Action

1

High voltage contacts

Check the high voltage contacts on the right side frame to ensure
they fit securely and are not pitted, contaminated, or damaged. If
incorrect, replace the contact with one from the HV contact kit.
Screws are included to attach the contacts to the right side frame in
the HV contact kit.

2

Charge roll conductive
bushing

Make sure the charge roll bushing is correctly installed in the right
charge roll arm.

3

HVPS

Check the voltages on J22-1 thru J22-8. If incorrect, replace the
system board.

4

HVPS cable
(part of front
harness cable)
System board

Check the continuity of the HVPS cable. If incorrect, replace the
cable assembly. If correct, replace the system board.

Print quality–blank page.
FRU

Action

1

Print cartridge

Check the print cartridge for damage, especially the PC drum contact
on the cartridge.

2

High voltage contact

Check the PC drum contact on the right side frame for damage, PC
drum contact wear or contamination. If the contact is bent or
damaged, replace the contact.
Note: Inspect the HVPS PC drum contact on the board for damage
or contamination.

3

HVPS

Check the fuse on the HVPS. If open, replace the HVPS. Check the
voltages at J22 on the system board. Measure the following voltages
from connector J22 to printer ground:
• Printer Idle
J22-5 measures +24 V dc
• Printer Printing
J22-5 measures +24 V dc
If the voltages at J10-5 are incorrect, replace the system board.

4

Front cable harness HVPS
section

Check the front cable harness at J22 on the system board and at
CN1 on the HVPS to make sure the harness is connected properly. If
connected properly, check the continuity of the cable harness. If there
is no continuity, replace the front cable harness.

5

Printhead assembly

Generally a 93x service error is posted if the printhead assembly fails
and the printer does not give a blank copy symptom.
The printhead used in the printer does not have a mechanical shutter
as previous laser printers. The printer is interlocked through the front
top cover interlock switch.

Diagnostic information

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Print quality–random marks
Service tip: The primary cause of random marks is due to loose material moving around inside the
printer and attaching to the photoconductor, charge roll, or transfer roll.

1

Symptom

Action

Random marks

Check the print cartridge for loose or foreign material that might be
on the photoconductor. Check the transfer roll and charge roll for any
pieces of material that are stuck to the rolls.

Print quality–blurred or fuzzy print
Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly, alignment
assembly, any feed roller, or in the transfer roll bearings or transfer roll. Check the gearbox assembly
for correct operation. Check the transfer roll for binds or a contaminated shaft or bearings.
Blurred print can also be caused by incorrect feeding from one of the input paper sources, paper
trays, duplex option, or envelope feeder.
Check the high voltage contacts to ensure they are not bent, corroded, or damaged. Replace as
necessary.

Print quality–evenly spaced horizontal lines or marks
FRU

Action

1

Lines spaced 3.19 mm
(.126 inch) apart

This can be caused by the motor pinion gear on the main drive motor.
Replace the main drive motor.

2

Lines spaced 22.32
mm(.882 inch) apart
Lines spaced 28.7 mm
(1.130 inch) apart
Lines spaced 47.83 mm
(1.883 inch) apart
Lines spaced 63.77 mm
(2.511 inch) apart

This can be caused by a defective gear in the main drive gearbox
assembly. Replace the main drive gearbox assembly.

3

Lines spaced 38.26 mm
(1.506 inch) apart

This can be caused by defective gear(s) in the main drive gearbox.
Replace the FRUs in the following order:
• Main drive gearbox
• Reference edge

4

Lines spaced 44.64 mm
(1.757 inch) apart

Replace the FRUs in the following order:
• Developer drive assembly
• Main drive gearbox assembly

5

Lines spaced 47.19 mm
(1.858 inch) apart

Replace the FRUs in the following order:
• Toner cartridge
• Charge roll
• Developer drive assembly

6

Lines spaced 49.16 mm
(1.935 inch) apart

Replace the toner cartridge.

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FRU

Action

7

Lines spaced 49.74 mm
(1.958 inch) apart

Replace the FRUs in the following order:
• Redrive assembly
• Fuser assembly
There is a danger from hazardous voltage in the area of
the printer where you are working. Unplug the printer
before you begin, or use caution if the printer must
receive power in order to perform the task.

8

Lines spaced 51.02 mm
(2.009 inch) apart

Replace the transfer roll.

9

Lines spaced 52.23 mm
(2.056 inch) apart

Replace the redrive assembly.

10

Lines spaced 76.53 mm
(3.013 inch) apart

Replace the FRUs in the following order:
• Alignment assembly
• Main drive gearbox assembly

11

Lines spaced 95.66 mm
(3.766 inch) apart

Replace the FRUs in the following order:
• Toner cartridge
• Main drive gearbox assembly

12

Lines spaced 99.49 mm
(3.917 inch) apart

Replace the redrive assembly.

13

Lines spaced 114.79 mm
(4.519 inch) apart

Replace the alignment assembly.

Diagnostic information

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Print quality–background
Service tip: Some background problems can be caused by rough papers, non-Lexmark toner
cartridges or if the media texture is set to the rough setting.
Some slick or coated papers may also cause background. Some problems occur with printers that
run a large amount of graphics in a humid environment. The customer may try to improve the print
quality by increasing the transfer setting.
Check the charge roll to make sure it is not at the end of life.
FRU

Action

1

Printhead

The printhead on the Lexmark T printers cannot be cleaned. Try
another printhead if all other attempts fail to correct a background
problem.

2

Transfer roll assembly

Check the high voltage contact from the HVPS to the transfer roll.
Check the transfer arm assembly right side bearing for
contamination, pitting, or a loose cable to the bearing. If any
problems are found, replace the defective part. Check the transfer roll
shaft for contamination, wear, or pitting on the ends of the shaft that
go into the bearings. If a problem is found, clean the ends of the shaft
or replace the transfer roll assembly.

3

High voltage contacts

Check the high voltage contacts on the right side frame to ensure
they are clean and not bent, deformed, or pitted. If incorrect, replace
the contact.

4

System board HVPS
connector

Check the following voltages at J22 on the system board. Measure
the voltages from J22 to printer ground.
Pin

Voltage (approximate)

Printer idle
J22-1

0 V dc

J22-2

+4 V dc

J22-4

0 V dc

Printer printing
J22-1

0 V dc to +5 V dc

J22-2

0 V dc to +4 V dc

J22-4

0 V dc to +1.9 V dc

If J22-1 voltage is incorrect, check the continuity of the front harness
cable (J22-1 line). If there is no continuity, replace the harness cable.
If there is continuity, replace the HVPS. If this does not correct the
problem, replace the system board.
If J22-2 voltage is incorrect or if the voltage remains at 0 V dc, check
the continuity of the front harness cable (J22-2 line). If there is no
continuity, replace the harness cable. If there is continuity, replace the
HVPS. If this does not correct the problem, replace the system board.
If J22-4 voltage is incorrect, check the front harness cable (J22-3
line). If there is not continuity, replace the harness cable. If correct,
replace the system board. if this does not correct the problem,
replace the HVPS.

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Print quality–banding
Service tip: Banding is difficult to detect except on a page with a uniform gray or a large amount of
graphics printed on the page. Banding is primarily due to a variation in the speed of the paper as it
feeds through the printer, especially in the development and transfer process. Inspect the alignment
assembly, main drive assembly, and all other paper feed components for signs of wear, dirt, binds, or
damage, especially the drive gears. Banding appears as light or dark horizontal lines on a uniformly
gray page.
Banding can also be caused by a defective charge roll brush contact or HVPS. Check the charge roll
contact for damage and for proper connection to the HVPS and print cartridge.

Print quality–black bands on outer edges of the page
This print quality problem appears as vertical black bands on one or both sides of the copy and can
be wide, narrow, light, or dark.
FRU

Action

1

Charge roll counterbalance
springs

If the problem is just on one side of the page, check the charge roll
counterbalance spring on that side. You can check to see if enough
force is being applied to the charge roll by applying a slight downward
pressure with your finger to the charge roll link arm that the spring is
attached to while you run a print test sample. See if the problem
changes or goes away. If this fixes or changes the problem, then
check the springs and charge roll link arm assemblies for binds or
defective parts. Replace as necessary.

2

Charge roll assembly
Charge roll link arm

Check the charge roll for toner buildup or other contamination on the
outer edges that correspond to the bands on the page. Check the
charge links and arms for proper operation, binds or incorrectly
mounted counterbalance springs. Repair or replace as necessary.

3

HVPS

Check the following voltages at J22-8 on the system board:
• Printer Idle
J22-8 measures 0 V dc
• Printer Printing Test Page
J22-8 voltage changes from 0 V dc to +4 V dc
If the voltage does not vary, check the continuity of line J22-8 in the
front cable harness. If there is no continuity, replace the cable
harness. If there is continuity, replace the HVPS. If this does not
correct the problem, replace the system board.
Turn the printer off and check the resistance between J22-7 and
printer ground. The resistance measures approximately 0 ohms. If
incorrect, make sure the system board is mounted correctly and
securely grounded. If correct, replace the system board.

Print quality–residual image
Service tip: Install a new print cartridge if available before doing this service check. Residual image
can be caused by the photoconductor, cleaning blade, and other parts inside the print cartridge.

1

FRU

Action

Hot roll fuser assembly

Check the fuser assembly for toner contamination. The hot roll
especially might cause toner to be retained and deposited on the
page.

Diagnostic information

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4060-xxx

Print quality–light print
Service tip: Check the toner saver and print darkness settings first if the print is light.
FRU

Action

1

Transfer roll

Check the right end of the transfer roll shaft for signs of wear or
contamination. If incorrect, replace the transfer roll.

2

Right side transfer roll arm
assembly
HVPS

Check the right side transfer roll arm assembly bearing for wear or
contamination. Also make sure the transfer cable is firmly attached to
the bearing. If incorrect, replace the right side transfer arm assembly.
Check the connection of the transfer roll assembly cable to the
transformer on the HVPS board. Check the continuity of the cable
from the bearing to the spade terminal on the cable. If incorrect,
replace the right side transfer arm assembly. If correct, replace the
HVPS.

3

Printhead

A contaminated printhead may be the cause of light print. If no other
cause is found, install a new printhead.

Print quality–toner on backside of printed page
Service tip: This is generally caused by loose toner in the machine in the paper path being carried
through the printer on the backside of the paper.
FRU

Action

1

Hot roll fuser assembly

Toner is being carried out on the backside of the media. This problem
is generally caused by a toner buildup on the fuser hot roll or backup
roll. Check the fuser hot roll and backup roll for any noticeable
buildup of toner. Repair as necessary.

2

Transfer roll transfer plate
assembly

Check the transfer roll for toner buildup or loose toner around the
area of the transfer plate assembly. Clean the area and run another
copy. If the problem continues, replace the FRUs in the following
order:
• HVPS
• System board

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Smart contact assembly service check
Note: If you are unable to clear a “32-Unsupported Cartridge” User Error message, be sure a
Lexmark T63x print cartridge is correctly installed in the printer. The cartridge is easily identified by
the contact board on the right side rear of the cartridge. Install another print cartridge before
attempting to troubleshoot the printer. Make sure the smart cable is properly connected to J19 on the
system board. Check the print cartridge for damage or improper installation of the smart chip. Also,
be sure there is proper contact between the smart chip on the cartridge, and the smart contact
assembly.
Service tip: An intermittent “32-Unsupported Cartridge” User Error message can be caused by poor
contact between the smart cartridge contacts in the upper front cover and the smart chip. Also check
for proper seating of the smart cartridge cable to the system board.

1

FRU

Action

Smart contact assembly
System board

Check the voltage on the smart cartridge contact. The voltage
measures approximately +3.8 V dc when not writing data to the
system board. If data is being written, the voltage measures
approximately 0 V dc. If incorrect, disconnect the cable from J19 on
the system board and check the voltage on J19-1. The voltage
measures approximately +5 V dc.
• If incorrect, replace the system board.
• If correct, replace the smart cartridge contact assembly.

Diagnostic information

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StapleSmart finisher service check
Note: When removing the stapler mechanism from the option, first remove the staple supply
cartridge.
Note: When replacing staples in the supply cartridge, discard any old staples in the cartridge and
replace with a fresh strip.

Problems with static electricity buildup

1

FRU

Action

Top cover

Make sure the brush is attached to the top cover assembly, the
ground clips are installed, and the brush is grounded.

Printer does not recognize StapleSmart finisher option as being installed.
FRU

Action

1

StapleSmart finisher option

Ensure that the StapleSmart finisher is the only option that is not
recognized by the base printer. If the finisher is the only option not
recognized by the printer continue with step 2. If not, check the
autoconnects of the options not recognized and the interconnect
board and cable connectors.

2

Stapler motor/drive
assembly
stapler card assembly

Check the autoconnects for signs of damage, especially the
connector pins. Remove the right side cover and check the cables at
J1A, J1B (bottom autoconnect), J14A, J14B (top autoconnect) to the
stapler card assembly to make sure they are attached securely.
Check the voltages at the printer top autoconnect. If incorrect,
remove the finisher option and go to “Autoconnect” on page 5-1. If
voltages are correct, reinstall the finisher option and check the
voltages at J1A and J1B on the connector. If correct, replace the
stapler card assembly. If incorrect, replace the stapler motor/drive
mechanical assembly.

Close Finisher Top Cover displayed–unable to clear or reset message. (POST
incomplete)
FRU

Action

1

Top cover assembly

Check the top cover assembly to ensure that it is actuating the top
cover switch and the cover is opening and closing correctly.

2

Top cover switch stapler
card assembly

Check continuity of the stapler top cover open switch. If incorrect,
replace the switch assembly. If correct, replace the stapler card
assembly.

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Close Finished Side Door displayed–unable to clear or reset message. (POST
incomplete)
FRU

Action

1

Side cover door

Check the stapler access door for any signs of damage or broken
parts. Make sure the door correctly actuates the stapler side access
door switch.

2

Side cover door switch
Stapler card assembly

Check the continuity of the stapler access door switch. If incorrect,
replace the stapler access door switch assembly. If correct, replace
the stapler card assembly.

POST incomplete–stapler cycles several times.

1

FRU

Action

Stapler assembly

Replace the stapler assembly.
Note: When replacing the stapler assembly, observe the location of
the ground lead from the stapler assembly and the finisher frame.
Make sure the ground lead is correctly reattached.

Diagnostic information

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4060-xxx

990 Service Error Code - Check Bin x displayed–POST Incomplete
• “Step 1–During POST the stapler option does not try to home.” on page 2-88.
• “Step 2–During POST the stapler option tries to home.” on page 2-88.
Step 1–During POST the stapler option does not try to home.

1

FRU

Action

Stapler card assembly
Drive motor assembly

Turn the printer off, disconnect the motor from J2 and check for
continuity between J2 pins 1, 2, 5, and 6 on the cable and the motor
case. If you get continuity, replace the motor drive assembly. If you do
not measure continuity, continue with this step.
Reconnect J2 and check the voltages on connector J2.
Note: All voltages are approximate values.
Pin No. Voltage static

Voltage
feeding

1

+24 V dc

+24 V dc

2

+24 V dc

Varies +11.4 V dc to +24 V dc

3

Not used

4

Ground

5

+5 V dc

Varies +3.6 V dc to +5 V dc

6

+5 V dc

+5 V dc

If the voltages are correct, replace the motor drive assembly. If the
voltages are incorrect, replace the stapler card assembly.

2

Drive motor assembly
(mechanical)

Check the drive motor assembly (99A2513) for normal operation.
Normal operation for this assembly during POST is the motor turns,
the motor pinion gear turns, the drive gear turns, and the clutch
rotates and sets.

Step 2–During POST the stapler option tries to home.
Note: When a 990 Service Error is displayed during POST, the failure is usually in the stapler
mechanical unit or stapler card.

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281 Paper Jam–The paper feeds partway into the standard bin even if finisher
is selected
Note: When a 900 Service Error is displayed during POST the failure is usually in the stapler
gearbox assembly or stapler cartridge.

1

FRU

Action

DC motor in drive gearbox
assembly
Stapler card assembly

Turn the printer off, disconnect the motor from J4 and check for
continuity between J4 pins 1, 2, 5, and 6 on the cable and the motor
case. If you get continuity, replace the drive gearbox assembly. If you
do not measure continuity, continue with this step.
Check the voltages on connector J4.
Note: All voltages are approximate values
Pin No. Voltage static

Voltage feeding

1

+24 V dc

+24 V dc

2

+24 V dc

Varies +11 V dc to +24 V dc

3

Not used

4

Ground

5

+5 V dc

Varies +3 V dc to +5 V dc

6

+5 V dc

+5 V dc

If the voltages are correct, replace the mechanical drive assembly. If
the voltages are incorrect, replace the stapler card assembly.

FRU

Action

1

Swing arm spring

Make sure the swing arm spring is connected and not loose or
broken.

2

Clutch assembly
Drive motor assembly
Drive gear

Check the clutch assembly on the right side frame assembly for
correct operation and broken or loose parts.
Check the drive motor assembly and drive gear for damage.

281 Paper Jam–The paper may jam at the upper deflector.
FRU

Action

1

Upper deflector

Check the upper deflector for signs of broken parts, especially the
hook that holds the upper deflector spring. Check for bowing of the
deflector. Make sure the deflector moves smoothly and freely with no
signs of binds.

2

Upper deflector spring

Make sure the upper deflector spring is not loose or broken.

Diagnostic information

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281 Paper Jam–paper jams into stapler output bin.
FRU

Action

1

Center stapler bail

Check the center stapler bail for broken parts and that the bail moves
freely on the upper exit shaft assembly.

2

Upper exit shaft assembly
Lower exit shaft assembly
Exit shaft bearings

Check the upper and lower shaft assembly for wear, binds, or
damage. Check the exit shaft bearings for damage or binding.

282 Staple Jam - Check Stapler displays.

1

FRU

Action

Stapler assembly

Check the stapler assembly for broken or damaged parts.

POST incomplete–Insert Stapler Cartridge displays (cartridge holder is
installed and cannot clear message)
When this failure occurs, the following may also occur in the order shown:

• Insert Staple Cartridge displayed.
The stapler assembly may cycle or fire a few times.

• 282 Stapler Jam displayed.
The stapler assembly may try to cycle or fire.
990 Service - Check Bin 1 displayed.

•

FRU

Action

1

Stapler cartridge holder
Stapler assembly

Before proceeding with the service check, gently try to remove the
stapler cartridge holder from the stapler assembly. If the holder is
jammed in the stapler assembly:
1. Turn the printer off and remove the right side cover. Use care
when removing the cover as the right side door switch and cable
assembly are easily damaged. Do not allow the right side cover to
hang by the switch and cable assembly.
2. Disconnect the 10 pin cable from the stapler assembly.
3. Hold the stapler assembly with one hand while removing the
three screws from the assembly. The assembly is heavy and easy
to drop.
4. Check the stapler assembly for damaged or broken parts. Check
the flag and spring assembly on the front of the stapler assembly
to see if the flag or spring are broken or missing. If any problem is
found, replace the stapler assembly. If no problem is found,
continue with step 5.
5. Carefully cycle the large gear on the side of the stapler assembly
and try to free the cartridge holder assembly. Note: Look for
staples jammed at the throat of the cartridge holder and remove
any that are found. Gently try to remove the cartridge holder from
the stapler assembly. It may be necessary to manually cycle the
large gear on the side of the stapler assembly to release the
cartridge holder.
6. Reinstall the stapler assembly with a new stapler cartridge holder
and staples. Run the Finisher Feed Test to check the option. If the
problem continues, go to step 2.

2

Stapler to stapler board
(J3) cable

Check the continuity of the cable. If a problem is found, replace the
cable.

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3

FRU

Action

Stapler board
Stapler assembly

Check the voltages on connector J3 on the board.
Note: All voltages are approximate values.
Pin No. Voltage static

Voltage feeding

1

+24 V dc

+24 V dc

2

+24 V dc

+24 V dc

3

+24 V dc

+24 V dc

4

+24 V dc

+24 V dc

5

0 V dc

0 V dc

6

0 V dc

0 V dc

7

0 V dc

Varies (0 V -1.5 V dc)

8

GND

9

+5V dc

+5V dc

10

0 V dc

0 V dc

If the voltages are correct, replace the stapler assembly. If the
voltages are incorrect, replace the stapler board.

283 Staple Jam - Check Stapler displays.
FRU

Action

1

Staple cartridge holder

Check the staple cartridge holder for any signs of damage and for
any jammed staples in the cartridge. Replace the staple cartridge
holder if damaged. If staples are jammed in the cartridge, replace the
old strip of staples with a new strip and try the finisher feed test from
the diagnostic menu.

2

Staple unit

Remove the staple cartridge holder from the staple unit and remove
the staple unit. Check for any staples that might be in the staple unit
mechanism. Check for correct operation and for any signs of
damage.

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Paper feeds into finisher option output tray–Paper is not stapled–Paper
does not align with the right side.
FRU

Action

1

Paper alignment wheel
Paper alignment pad

Check to make sure the gamma wheel aligner assembly is operating
correctly and that the wheel is touching the paper. If the gamma
wheel is not turning or touching the paper, go to step 2. If the wheel is
turning and touching the paper, check the wheel for wear, damage, or
contamination. If any problem with the wheel is found, replace the
wheel.
Check to make sure the aligner assembly and pads are operating
correctly. Make sure the pads are touching the paper and moving the
paper to the right side frame. If the aligner pads are not moving into
the lower position and touching the paper, go to step 3. If the aligner
pads are touching the paper, make sure the pads are not worn,
damaged, or contaminated. Replace if necessary.

2

Paper wheel aligner
assembly

Check the paper wheel aligner assembly to make sure it is mounted
correctly. Check to make sure there are no broken gears or other
mechanical parts. If any are found, replace the aligner assembly. If no
problem is found, go to step 3.

3

Stapler board

Check to make sure the cable to J4 (Accessory) is properly
connected to J4 on the board. Turn the printer off, disconnect the
motor cable from J4, and check for continuity between J4 pins 1,2,3,
and 4 to the motor case. If you get continuity, replace the gearbox
drive assembly. If you do not get continuity, continue with the step.
Pin No. Voltage static
(Motor not running)

Voltage feeding
(Motor running)

1

+24 V dc

+24 V dc

2

+24 V dc

Should vary when motor running

3

Not used

4

Ground

5

+5 V dc

Should vary when motor running

6

+5 V dc

+5 V dc

If the voltages are correct, replace the gearbox drive assembly. If the
voltages are incorrect, replace the stapler board.

Misalignment of sheets to be stapled.
FRU

Action

1

Left side bail assembly

Check the left side bail assembly for any signs of binding, missing, or
broken parts.

2

Stapler gearbox assembly

Check the stapler gearbox assembly for correct operation.

Sheets are transported into output tray but not stapled.

1

FRU

Action

Sol 1, stapler drive
Stapler assembly
Stapler card assembly

Disconnect Sol 1 cable from J5 on the stapler card and measure the
resistance of the solenoid across the cable connector. It should
measure approximately 48 ohms (when cold). If incorrect, replace the
stapler/finisher option assembly. If correct, replace the stapler card
assembly.

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Stapled sheets are not transported to the output tray.

1

FRU

Action

Sol 2 (stapler gearbox
assembly)
Stapler card assembly

Disconnect Sol 2 cable from J8 on the stapler card and measure the
resistance of the solenoid across the cable connector. It should
measure approximately 48 ohms (cold). If incorrect, replace the
stapler/finisher option assembly. If correct, replace the stapler card
assembly.

POST incomplete–stapler cycles several times

1

FRU

Action

Stapler assembly

Replace the stapler assembly.
Note: When replacing the stapler assembly, observe the location of
the ground lead from the stapler assembly and the finisher frame,
and make sure the ground lead is correctly reattached.
(Flag or spring off stapler unit)
Will also happen when pin 7 of J3 is open.

Toner sensor service check
Service tip: Check the print darkness menu setting before checking the toner sensor.
This service check is intended to be used when a 929 Service Error displays.
FRU

Action

1

Developer drive assembly

Incorrect operation of the developer drive assembly can cause the
printer to display a 929 error code (Toner Sensor). Check the
developer drive assembly for correct installation, any sign of worn,
loose, or broken parts.

2

Front harness cable

Check the toner sensor portion of the front harness cable to make
sure it is properly seated into the toner sensor. If correct at both the
sensor and system board (J22), check the continuity of the cable. If
incorrect, replace the cable.

3

Toner sensor

The toner sensor cable is part of the front harness and part of
connector J22 on the system board. Check the voltage at J22-11. It
reads approximately +5 V dc. If incorrect, replace the system board.
If correct, check the voltage at J22-12. It reads approximately +5 V dc
with the system board removed from the printer. If incorrect, replace
the system board. If correct, replace the toner sensor assembly. A
bad ground connection between J22-13 on the system board and pin
3 on the toner sensor results in a 929 service error.

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Transfer roll service check
Service tip: The transfer roll is 51.02 mm (2.009 inch) circumference. Any print quality problems such
as lines that are spaced 51.02 mm apart indicate you should check the transfer roll for damage and
check for toner or foreign material buildup.
Service tip: The transfer roll assembly is part of the maintenance kit and is replaced when an 80
Scheduled Maintenance displays. Ask the customer if they have replaced the transfer roll recently.
CAUTION: Make sure the printer is unplugged before making any checks on the
transfer roll or associated parts for personal safety and to prevent damage to the printer.

FRU

Action

1

Transfer roll assembly

Check the transfer roll for toner buildup, surface damage to the roll,
oil, or other contaminants on the surface of the roll. Replace the
transfer roll as necessary.

2

Left transfer arm assembly

Check the left transfer roll arm assembly to make sure it is fastened
and locked in the down position. If the arm is not locked down, make
sure the arm is not broken and locks into the EP frame correctly.
Check the left transfer arm assembly spring for proper operation.

3

Right transfer arm
assembly

Check the right transfer arm assembly to make sure it is fastened and
locked in the down position. If the arm is not locked down, make sure
the arm is not broken and locks into the EP frame correctly. Check
the right transfer arm assembly spring for proper operation. For any
background problems, ensure the contact to the HVPS board is
correct and that there is approximately 0 ohms resistance between
the transfer roll shaft and the HVPS contact. If correct, go to “Print
quality–background” on page 2-82.

4

HVPS–917 Error code

Check the voltage at J22-3. The voltage changes from +24 V dc with
the printer idle to 0 V dc when the printer runs the print test. If the
voltage is incorrect, check the continuity of line J22-3 in the front
cable harness to the HVPS. If there is no continuity, replace the cable
harness. If there is continuity, replace the HVPS. If the problem
continues, replace the system board.

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3. Diagnostic aids
This chapter explains the tests and procedures to identify printer failures and verify repairs have
corrected the problem.
To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic
Mode.

Diagnostics mode
Entering Diagnostic Mode:
1.
2.
3.
4.

Turn the printer off.
Press and hold the Go and Return buttons.
Turn the printer on.
Release the buttons when Performing Self Test displays on the operator panel.

Available tests
The tests display on the operator panel in the order shown:

•
•
•
•
•
•
•
•
•
•
•
•

Print Registration
Print Tests
Hardware Tests
Duplex Tests (if installed)
Input Tray Tests
Output Bin Tests
Finisher Tests (if installed)
Base Sensor Test
Device Tests (displayed only if flash or disk option is installed)
Printer Setup
EP Factory Defaults
Error Log

Exiting Diagnostics Mode
Select Exit Diagnostics to exit the Diagnostics Mode and return to normal mode.

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Device tests
Quick Disk Test
This test performs a non-destructive read/write on one block per track on the disk. The test reads one
block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in
the block. If the block is good, the saved data is written back to the disk.
To run the Quick Disk Test:

1. Select Quick Disk Test from the Device Tests menu.
• The power indicator blinks while the test is in progress.
• “Quick Disk Test/Test Passed” message displays if the test passes and the power indicator
turns on solid.

• “Quick Disk Test/Test Failed” message displays if the test failed and the power indicator
2.

turns on solid.
Press Go, Return, or Stop to return to the Device Tests menu.

Disk Test/Clean
Warning: This test destroys all data on the disk and should not be attempted on a good disk. Also
note that this test may run approximately 1 1/2 hours depending on the disk size.
To run the Disk Test/Clean Test:

1. Select Disk Test/Clean from the Device Tests menu.
2.

3.

4.

“Files will be lost/Go or Stop?” message displays to warn the user that all contents on the disk
will be lost.
To exit the test immediately and return to the Device Tests menu, press Return/Stop. To
continue with the test, press Go.
If Go is selected, “Disk Test/Clean/BAD:000000 00%” message displays. The screen updates
periodically indicating the percentage of test completed and the number of bad blocks found.
The power indicator blinks during the test. The test can be canceled anytime during the test by
pressing Return/Stop.
• Once the test is complete, the power indicator turns on solid and a message displays.
• “xxxx Bad Blocks/yyyyyy Usable” message displays if fewer than 2000 bad blocks are
detected. xxxx indicates the number of bad blocks and yyyyyy indicates the number of
usable blocks.
• “xxxx Bad Blocks/Replace Disk” message displays if more than 2000 bad blocks are
detected. The disk cannot be recovered because too many bad blocks exist on the disk.
Press Go or Return/Stop to return to the Device Tests menu.

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Flash Test
This test causes the file system to write and read data on the flash to test the flash.
Warning: This test destroys all data on the flash because the flash is reformatted at the end of the
test.
To run the Flash Test:

1. Select Flash Test from the Device Tests menu.
• The power indicator blinks while the test is running.
• “Flash Test/Test Passed” message displays if the test passes and the power indicator turns

2.

on solid.
• “Flash Test/Test Failed” message displays if the test fails and the power indicator turns on
solid.
Press Go or Return/Stop to return to the Device Tests menu.

Disabling Download Emulations
• Error Code 964: Download Emulation CRC Failure. Checksum failure detected in the emulation
header or emulation file.

• Error Code 965: Download Emulation Outdated. Time stamps indicate the download emulation
and RIP code are incompatible.
To help resolve download emulation problems the following steps are necessary to instruct the printer
to POR without activating any download emulations.
To disable the download emulation:

1. Turn the printer off.
2. Press and hold the Go and Menu buttons.
3. Turn the printer on and release the buttons once “Performing Self Test” displays.
4.
5.

Once the printer is idle, the emulation can be downloaded again.
Program the download emulation into the code overlay card assembly again.
If these steps do not resolve the problem, replace the code overlay card assembly and
download the emulation again.

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Duplex tests
Duplex Quick Test
This test is used to verify that the Duplex Option Top Margin is set correctly. This test prints a
duplexed version of the Quick Test Page that can be used to adjust the Top Margin for the backside of
the duplexed page. You can run one duplexed page (Single) or continue printing duplexed pages
(Continues) until Return/Stop is pressed.
The paper you choose to print the page on should be either Letter or A4.
To run the Duplex Quick Test:

1. Select Duplex Quick Test from the menu.
2. Select Single or Continuous.
• The single Duplex Quick test cannot be canceled.
• The printer attempts to print the Quick Test Page from the default paper source. If the
default paper source only supports envelopes, then the page is printed from Tray 1.

• Check the Quick Test Page for the correct offset between the placement of the first scan

3.

line on the front and back side of a duplexed sheet.
• If adjustment is necessary the Top Margin Offset must be adjusted first. The range of the
adjustment is -25 to +25. The Duplex Top Margin Offset range is -20 to +20.
• Adjustment of this setting lets you shift up or down the position of the Top Margin. Changing
this parameter by 1 unit moves the margin 1/100 inch. A positive offset moves the text
down the page and widens the top margin while a negative offset moves the text up the
page and narrows the top margin.
Press Return/Stop to exit the test.

Check the Top Margin Offset of the base printer.

Duplex Sensor Test
This test is used to determine whether or not the duplex sensors and switches are working correctly.

1. Select Sensor Test from the Duplex Tests menu.
2. Manually actuate each of the duplex sensors. When the sensor/switch is closed, CL (closed)

3.

displays, when the sensor/switch is open, OP (Open) displays.
• Duplex input sensor
• Duplex exit sensor
Press Return/Stop to exit the test.

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Duplex Motor Test
This test lets you test the duplex option paper feed drive system, and verify that the power and
velocity values are acceptable.
To run the Duplex Motor Test:

1. Select Motor Test from the Duplex Tests menu. The duplex motor test continues to run until the

2.

printer is powered off.
• The power indicator blinks while the test is running.
• The duplex option runs the motor at a high speed and then a low speed and takes an
average of the power required for each speed.
• After all the information is computed, the motor turns off.
DUPLEX MOTOR AA BB CC DD EE FF
appears on the printer display.
To pass the test the following results must display:
AA = 00
BB = in the range of 20 through 3F inclusively (hex)
CC = in the range of 3A through 5D inclusively (hex)
DD = in the range of 11 through 1F inclusively (hex)
Ignore bytes EE and FF.
If the test fails, remove the drive belt from the duplex DC motor and run the motor test
again. For the duplex DC motor to pass the test the following results must display:
AA = 00
BB = in the range of 29 through 3E inclusively (hex)
CC = in the range of 35 through 51 inclusively (hex)
DD = in the range of 0C through 13 inclusively (hex)
For the duplex drive system to pass the test the following results must display:
AA = 00
BB = in the range of 29 through 3F inclusively (hex)
CC = in the range of 3A through 5D inclusively (hex)
DD = in the range of 11 through 1F inclusively (hex)
Press Return/Stop to exit the test.

Duplex Feed 1 Test
This test feeds a blank sheet of paper to the duplex paper stop position 1.
To run the Duplex Feed 1 Test:
Select Duplex Feed 1 from the Duplex Test menu.

• The power indicator blinks while the paper is feeding.
• “Duplex Feed 1/Feeding” message displays while the paper is feeding through the printer.
• “Duplex Feed 1/Clear Paper” message displays when the paper reaches paper stop position 1
and the power indicator turns on solid.

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Duplex Feed 2 Test
This test feeds a blank sheet of paper to the duplex paper stop position 2.
To run the Duplex Feed 2 Test:
Select Duplex Feed 2 from the Duplex Test menu.

• The power indicator blinks while the paper is feeding.
• “Duplex Feed 2/Feeding” message displays while the paper is feeding through the printer.
• “Duplex Feed 2/Clear Paper” message displays when the paper reaches the duplex paper stop
position 2 and the power indicator turns on solid.

Error log
Viewing the error log
The error log provides a history of printer errors. It contains the 12 most recent errors that have
occurred on the printer. The most recent error displays in position 1 and the oldest error displays in
position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is
discarded. Identical errors in consecutive positions in the log are entered. All 2xx and 9xx error
messages are stored in the error log.
To view the error log:

1. Select Display Log from the Error Log menu. The error log displays on three screens as only
four entries display at a time.
ERROR LOG
Display Log

2. To move to the next screen press Menu.
3. Press Return/Stop to exit the Error Log.

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Printing the error log
Additional diagnostic information is available when you print the error log. Some of the additional
information includes:

•
•
•
•

Detailed printer information
Time and date stamps
Page counts for each error
Sub error code information for each 9xx or 2xx error
Note: The 900 error code does not have sub error codes.
Model and
Serial number
Printer information

Page count
Panel display
when error occurred
Sub error codes

Next error code

The printed error log can be faxed to Lexmark or your next level of support for verification or
diagnosis.
To print the error log:

1. Select Print Log from the Error Log menu.
ERROR LOG
Print Log

2. To move to the next screen, press Menu.
3. Press Return/Stop to exit the Error Log menu.

Diagnostic aids

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Clearing the error log
1. Select Clear Log from the Error Log menu.
ERROR LOG
Clear Log

2. Select YES to clear the Error Log or NO to exit the Clear Log menu. If YES is selected, Empty
3.

Error Log displays on the screen.
Press Return/Stop to exit the Clear Log menu.

Hardware tests
Select the following Hardware Tests from this menu:

•
•
•
•
•
•
•
•

LCD Test
Button Test
DRAM Memory Test
ROM Memory Test
Parallel Wrap (if available)
Serial Wrap (if available)
Serial 1 Wrap (if available)
Serial 3 Wrap (if available)

LCD Test
1. Select LCD Test from the Diagnostic menu. The LCD test continually executes the LCD display
2.

test.
Press Return/Stop to cancel the test.

Button Test
1. Select Button Test from the Diagnostic menu. With no buttons pressed, several OP (Open)
2.
3.

appear on the display.
Press each button one at a time and a CL (Closed) displays in place of an OP. The proper
operation of each button can be checked.
Press Return/Stop to cancel the test.

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SDRAM Memory Test
The purpose of this test is to check the validity of SDRAM, both standard and optional. The test
writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly.
To run the SDRAM Memory Test:

1. Select SDRAM Memory Test from the menu. The power indicator blinks indicating the test is in
progress.

2. Press Return/Stop to exit the test.
P:###### represents the number of times the memory test has passed and finished successfully.
Initially 000000 displays with the maximum pass count being 999,999.
F:##### represents the number of times the memory test has failed and finished with errors. Initially
00000 displays with the maximum fail count being 99,999.
Once the maximum pass count or fail count is reached, the test is stopped, the power indicator is
turned on solid, and the final results display. If the test fails, the message SDRAM Error, displays for
approximately three seconds and the failure count increases by 1.

ROM Memory Test
The ROM Memory Test is used to check the validity of the controller board code and fonts.
To run the ROM Memory Test:

1. Select ROM Memory Test from the menu. P and F represent the same numbers for DRAM. The

2.

power indicator blinks indicating the test is in process. The test runs continuously.
Each time the test finishes, the screen updates with the result. If the test passes, the Pass
Count increases by 1, however if the test fails, one of the following messages displays for
approximately three seconds: ROM Checksum Error or ROM Burst Read Error. Once the
maximum pass count or fail count is reached, the test stops with the power indicator on solid.
The results appear on the screen.
Press Return/Stop to exit the test.

Parallel Wrap Test
This test is used with a wrap plug to check operation of the parallel port hardware. Each parallel
signal is tested.
To run the Parallel Wrap Test:

1. Disconnect the parallel interface cable and install the wrap plug (P/N 1319128).
2. Select Parallel Wrap Test from the menu. The power indicator blinks indicating the test is in

3.

progress. The test runs continuously until canceled.
Each time the test finishes, the screen updates. If the test passes, the Pass Count increases
by 1, however if the test fails, a message displays for approximately three seconds. Once the
maximum count is reached the test stops. The power indicator goes on solid and the final results
display.
Press Return/Stop to exit the test.

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Input tray tests
Input Tray Feed Test
This test lets the servicer observe the paper path as media is feeding through the printer. A blank
sheet of paper feeds through the printer as the laser turns off during this test. The only way to
observe the paper path is to open the lower front door that is used to access the envelope or
multipurpose feeder. The paper is placed in the output bin.
To run the Input Tray Feed Test:

1. Select Input Tray Feed Test from the menu.
2. Select the input source from the sources displayed on the Feed Test menu. All installed sources
3.
4.

are listed.
Select either Single (feeds one sheet of media from the selected source) or Continuous
(continues feeding media from the selected source until Return/Stop is pressed).
Press Return/Stop to exit the test.

Input Tray Sensor Test
This test is used to determine if the input tray sensors are working correctly. To run the Input Tray
Sensor Test:

1. Select the Sensor Test from the Input Tray Test menu.
• “Input Tray/Emptying/Pass=OP” message displays.
• EM = Input Tray Empty Sensor
• LO = Input Tray Paper Low Sensor
• P = Input Tray Pass Thru Sensor
2. Once this message displays, the servicer can manually actuate each sensor. The tray empty
3.

sensor can be actuated by hand, however a sheet of paper can be used to cover the pass thru
sensor. When the sensor is closed, CL displays, when the sensor is open, OP displays.
Press Return/Stop to exit the test.

The multipurpose tray and the envelope feeder do not have a paper low sensor. The multipurpose
tray does not have a pass thru sensor.
Tray sensor support by source
Source

Tray empty sensor

Paper low sensor

Pass thru sensor

Tray 1

YES

YES

NO

Tray 2

YES

YES

YES

Tray 3

YES

YES

YES

Tray 4

YES

YES

YES

Tray 5

YES

YES

YES

Multipurpose tray

YES

NO

NO

Envelope feeder

YES

NO

YES

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Output Bin Tests
Output Bin Test—Standard Bin
This test is used to verify if the standard bin sensor is working correctly.
To run the Standard Bin Sensor Test:

1. Select Output Bin Tests from the Diagnostic menu.
2. Select Output Bin Tests - Sensor Tests.
3. Select Sensor Tests - Standard Bin. “Standard Bin/Full=CL” message displays.

4.

Manually actuate the bin sensor by moving the flag in and out of the sensor. The display
indicates OP (open) when the flag is out of the sensor and CL (closed) when the flag is in the
sensor.
Press Return/Stop to exit the test.

Output Bin Feed Test
Note: If the Configure Bins printer setting is link rather than mailbox, the printer selects its own
internal bin linking regardless of which output bin is selected for the feed test
This test is used to verify that media can be fed to a specific output bin. No information is printed on
the media fed to the output bin because the printhead is not turned on during this test. This test can
be run from any input source and will support any size paper or envelope supported by the printer.
To run the Output Bin Feed Test:

1. Select Feed Test from the Output Bin Test menu.
2. Select the output bin you want the paper to exit into. The standard bin as well as any output
3.
4.

option bin installed on the printer is shown on the menu. (The output bin displayed is in the order
installed on the printer.)
Select either Single (one sheet of media feeds to the selected output bin) or Continuous
(media continues feeding to the selected output bin) until Return/Stop is pressed.
Press Return/Stop to exit the test.

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Feed to All Bins Test
This test can be used to verify that the printer can feed media to the standard bin or any installed
output options. No information will be printed on the test pages as the printhead is not turned on
during the feed test.
To run the Feed to all Bins Test:
Select Feed to all Bins Test from the menu.

• The media feeds from the default paper source.
• The printer feeds a separate piece of media to the standard bin first, then it feeds a separate
piece of media to each output bin installed in the following order:
Sheets fed

Output bins

Sheets fed

Output bins

Sheets fed

Output bins

1

Standard bin

9

Bin #8

17

Bin #5

2

Bin #1

10

Bin #9,

18

Bin #4

3

Bin #2

11

Bin #10

19

Bin #3

4

Bin #3

12

Bin #10

20

Bin #2

5

Bin #4

13

Bin #9

21

Bin #1

6

Bin #5

14

Bin #8

22

Standard bin

7

Bin #6

15

Bin #7

8

Bin #7

16

Bin #6

The test is continuous until either the Return or Stop button is pressed.

Output Bin Sensor Test
This test is used to determine whether or not the output bin sensor is working correctly for the
Standard Bin or the sensors are working for the output expander, high-capacity output stacker, 5-bin
mailbox or StapleSmart finisher, if installed.
To run the Output Bin Sensor Test for:

Standard Bin
1. Select Output Bin Test from the menu.
2. Select Output Bin Tests - Sensor Tests.
3. Select Standard Bin from the menu.
The following screen is displayed:
Standard Bin
F=OP

4.
5.

F=Standard Bin’s Bin Full Sensor
Once the screen is displayed, manually actuate the sensor flag to check the Bin Full Sensor.
When the sensor is closed, CL displays, and when the sensor is open OP displays.
Select Return or Stop to exit the test.

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Output Expander
1. Select Output Bin Tests from the menu.
2. Select Output Bin Tests - Sensor Tests.
3. Select Sensor Tests for Output Bin x (x=number of the output option to be tested)
The following screen is displayed:
Output Bin x
P=OP F=OP NF=OP

4.
5.

P=Pass Thru Sensor
F=Bin Full Sensor
NF=Near Full Sensor
Once the screen is displayed, manually actuate each of the output expander sensors. When the
sensor is closed, CL displays, and when the sensor is open OP displays.
Select Return or Stop to exit the test.

High-Capacity Output Stacker
1. Select Output Bin tests from the menu.
2. Select Output Bin Tests - Sensor Tests.
3. Select Sensor Tests for Output Bin x (x=number of the output option to be tested).
The following screen is displayed:
HC Bin x
TP=OP
P=OP F=OP NF=OP

4.
5.

TP=High-Capacity Stacker top position sensor
P=High-Capacity Stacker pass thru sensor
F=High-Capacity Stacker bin full sensor (lower part of dual sensor)
NF=High-Capacity Stacker near full sensor (upper part of dual sensor)
Once the screen is displayed, manually actuate each of the sensors of the high-capacity
stacker. When the sensor is closed CL displays, and when the sensor is open OP displays.
Select Return or Stop to exit the test.

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5-Bin Mailbox Option
1. Select Output Bin Tests from the menu.
2. Select Output Bin tests - Sensor Tests.
3. Select Sensor Tests for Output Bin x (x=number of the output option to be tested).
The following screen is displayed:
Output Bin x
P1=OP P2=OP L=NL

4.
5.

P1=5-Bin Mailbox first pass thru sensor
P2=5-Bin Mailbox second pass thru sensor
L=EM, 5-Bin x empty
L=NL, bin contains media, but the bin is NOT near full nor full
L=NF, the bin is near full
L=FL, the bin is full
Once the screen is displayed, manually actuate each of the sensors of the high-capacity
stacker, except for the output level sensor. When the sensor is closed, CL displays, and when
the sensor is open OP displays.
Select Return or Stop to exit the test.

Finisher Tests for StapleSmart Finisher
Finisher Feed Tests
This test is used to verify whether or not media can be fed to a finisher output bin and stapled. No
information is printed on the test pages as the printhead is not turned on. Eight sheets of paper feed
and then the pages staple.
Note: This test can be run using any of the paper sizes supported by the printer.
The media is fed from the selected source and then outputted to the finisher output bin.
To run the StapleSmart Finisher Feed Test:

1. Select Finisher Tests from the menu.
2. Select Feed Tests from Finisher Tests menu.
3. The feed test runs (may take a minute for the test to complete).
Eight sheets of paper feed into the finisher and then are stapled.
Note: This test cannot be stopped until the test is completed.

4. Select Return/Stop to exit the test.

Finisher Sensor Tests
This test can be used to verify whether or not the finisher sensors are working correctly.
To run the Finisher Sensor Test:

1. Select Finisher Tests from main menu.
2. Select Sensor Tests from the Finisher Tests menu.

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There are four sensor tests that can be selected from the Sensor Tests:

•
•
•
•

Staple Sensors
Cover and Door sensor
Pass and Media Sensor
Bin Level Sensor

Select the test for the sensors you want to test from the menu. The following appear on the display for
each test selected.

Staple Sensor Test
Staple
C=CL
SL=CL SP=CL H=CL
C=Cartridge present sensor
SL=Staple low sensor
SP=Self-priming sensor
H=Home signal sensor

Cover and Door Sensors
Cover and Door
TC=CL SD=CL
TC=Finisher top cover sensor
SD=Finisher stapler access door

Pass and Media Sensors
Pass and Media
P=OP M=OP
P=Finisher pass thru sensor
M=Finisher medium sensor

Bin Level Sensor
Bin Level
EM=OP NF=OP F=OP
EM=Finisher bin empty sensor
NF=Finisher bin near full sensor
F=Finisher bin full sensor
Once the screen is displayed for the test you have selected, manually actuate the sensor you want to
test. When the sensor is closed CL displays, and when the sensor is open OP displays.
Select Return or Stop to exit the test.

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Base Sensor Test
This test is used to determine if the sensors located inside the printer are working correctly.
The following sensors can be checked:

•
•
•
•
•

Toner optical sensor
Input sensor
Output sensor (fuser exit)
Narrow media sensor (fuser)
Cover closed switch (upper front cover)

To run the Base Sensor Test:

1. Select Base Sensor Test.
2.

The operator panel displays OP for open and CL for closed.
Manually toggle the sensors to verify that each sensor switches from open to closed.

Print registration
To set print registration:

1. Select Registration from the Diagnostic menu.
The Top margin sign/value pair blinks. This indicates it is the margin value being changed.
T=xxx*
L=xxx*

B=xxx*
R=xxx*

2. To select the margin value to be changed press Select until the margin value pair you want to
change is blinking.
The print registration range is:
Variable

Description

Value

B=

Bottom margin

-20 to +20 Each increment causes
approximately 55 mm shift in the
bottom margin

T=

Top margin

-25 to +25

L=

Left margin

-25 to +25

R=

Right margin

-10 to +10

3. To change the margin value press Menu. When the value you want displays, press Select to
save the value.

4. To exit the Registration menu, press Return.
To verify the margin values are correct you must print the “Quick Test Page” from the registration
screen. Press Go to print the test page. While printing the Quick Test Page the “Quick Test Printing”
message displays. Once the Quick Test Page completes printing, the Registration screen displays
again.
Print the Quick Test Page on letter or A4 paper.

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Printer setup
Setting the page count
This lets the servicer change the page count from the Diagnostics Menu. This is used whenever the
system board is replaced because this board contains the printer NVRAM Memory where the page
count is stored.
To set the page count:

1. Select Page Count from the Diagnostic menu.
• The current page count displays.
• The leftmost digit blinks, indicating it is the first digit to be changed.
2. Press Menu until the value you want displays.
3. Press Select to move to the next digit, and press Menu until the value you want displays.
4.
5.

Continue with each digit until you set the page count. You can skip any digit by pressing Select.
Press Select to save the new page count in NVRAM.
Press Return/Stop to exit the Diagnostic menu.

Viewing the permanent page count
The permanent page count can only be viewed and cannot be changed.
To view the permanent page count:

1. Select Permanent Page Count from the menu.
2. Press Return/Stop to exit the Diagnostic menu.

Maintenance page count
This counter is reset by the servicer after a 80 Scheduled Maintenance message displays
(300K copies) and a maintenance kit is installed.
To view the maintenance page count:

1. Select Maintenance Count Value from the Configuration menu.
2. Press Return to go to the previous menu.
To reset the maintenance page count to zero:

1. Select Reset Maintenance Count Configuration menu.
2. Pressing Select resets the maintenance page counter to zero.
Reset Maintenance Count Saved displays momentarily. When the reset operation is complete,
the menu returns to the Printer Setup Reset Maintenance Count screen.

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Setting configuration ID
The configuration ID is used to communicate information about certain areas of the printer that
cannot be determined using hardware sensors. The configuration ID is originally set at the factory
when the printer is manufactured, however it requires resetting whenever you replace the
interconnect board and can be set on the operator panel. However the configuration ID is the only
diagnostic function displayed until a valid ID is entered.
To set the configuration ID:

1.
2.
3.
4.

5.

Enter the Diagnostic mode.
Select Configuration ID from the Printer Setup menu.
At the prompt, enter the model name and serial number for your printer.
Enter the configuration ID.
• The current ID displays on the screen. The Configuration ID is on a label located inside the
printer. The label is attached to the top front cover hinge assembly and is visible when the
top front cover is open.
• The leftmost digit blinks indicating that it is the first digit to be changed.
To change the value, press Menu until the value you want is reached. Press Select to move to
the next digit, or press Select again to skip a digit. Change each digit as required. When the last
digit is changed, press Select to validate the Configuration ID. If the ID is invalid then “INVALID
ID” message displays on Line 2 before the ID displays. You have to reenter the Configuration ID
until a valid ID is verified. If the ID is valid then the ID is saved in NVRAM and the printer
automatically PORs to activate the new setting.

Note: When the printer PORs it does so in the normal mode.

Restore EP Factory Defaults
To restore each of the printer settings contained in the EP Setup menu to their factory default value
select Restore from the menu. To exit the menu without restoring the settings to the factory default
values, select Do Not Restore. Sometimes this is used to help correct print quality problems.

Fuser Temperature
This adjustment can be used to help solve some customer problems with paper curl on low grade
papers and problems with letterheads on some types of media.
The fuser temperature can be adjusted to: NORMAL, LOWER, LOWEST

Warm Up Time
You can change the amount of time the printer warms up before allowing pages to print by changing
this setting from 0 to 5. The factory sets the warm up at 0 or no warm up time. This time period lets
the backup roll heat up and helps reduce curl in some environments.

Transfer
The transfer can be adjusted to: LOW, MEDIUM, HIGH

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Print Contrast
The print contrast setting controls the developer voltage offset.
The print contrast can be adjusted to:
LOW, MEDIUM, HIGH

Charge Roll
The charge roll can be adjusted to:
LOW, MEDIUM, HIGH

Print tests
The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of
the installed input options. Each of the installed options is listed in the following order in the menu:
Tray 1
Tray 2 (if installed)
Tray 3 (if installed)
Tray 4 (if installed)
Tray 5 (if installed)
Multipurpose Feeder (if installed)
Envelope Feeder (if installed)
For each input source selected you have the following choices:

• Single (prints the Print Test Page once)
• Continuous (continue printing the Print Test Page until Return or Stop is pressed).
The contents of the Print Test Page varies depending on the media installed in the selected input
source.
Note: The Print Test Page always prints on one side of the paper, regardless of the duplex setting or
the presence of a duplex option.
If a source is selected that contains envelopes, an envelope test pattern is printed. If Continuous is
selected, the test pattern is printed only on the first envelope.
To run the Print Test Page:

1. Select Print Tests from the Diagnostic menu.
2. Select the media source.
3. Select Single or Continuous.
• If Single is selected no buttons are active during printing.
• If Continuous is selected, Return or Stop can be selected to cancel the test.
Check each Test Page from each source to assist in print quality and paper feed problems.

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Print quality test pages
The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner
cartridge lockout function disabled. The print quality test consists of three pages. Page one contains
a mixture of graphics and text. Pages two and three only contain graphics. If duplex is turned on, the
pages are duplexed. The Print Quality Test pages are printed in English and must always be printed
on letter, legal, or A4 paper.
Note: The print quality test pages can also be printed from the Configuration menu, however a
cartridge must be installed with a machine class ID matching the machine class ID stored in NVRAM.
Some diagnostic information may be printed on the pages when printing from this menu.
To run the Print Quality Test Pages:

1.
2.
3.
4.
5.

Turn the printer off.
Press and hold Select and Return.
Turn on the printer.
Release the buttons once Performing the Self Test displays.
The printer performs its normal POR cycle then prints one copy of the Print Quality Test pages.
If you want more than one copy, perform these steps again.

The following is printed:

• Diagnostic EP Setup:
Fuser temperature, warm up time, transfer, print contrast, and charge roll settings.

• Contents of the Diagnostic Error Log.
• Printer configuration information:
•

Printer serial number, controller code level, engine code level, operator panel code level, smart
option code levels, font versions, and so on.
Values for the Quality Menu settings used to print the pages.

Printing menu settings page
Note: This test page must be printed on letter, legal, or A4 paper.
To print the Menu Settings Page:

1. Select the TESTS MENU.
2. Select Print Menus from the TESTS MENU.
The page contains the following information:

• A list of all the printer settings contained in the operator panel menus and their values.
• A list of the installed options and features such as RAM memory cards, optional input paper
•

trays, envelope feeder, duplex option, output bins, flash, or disk.
Printer information such as serial number, page count, installed RAM, engine code level, RIP
code level, envelope feeder code level, tray 1-5 code levels, output bin 1-3 code levels, operator
panel code levels, font ROM version, and SRAM availability.

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Theory
Autocompensator operation
The autocompensator is a paper pick device that generates its own normal force. This force
generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very
gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary,
therefore no special trays are needed for card stock or labels. The gearing in the arm is designed so
the input torque from the motor produces a movement about the pivot of the arm. This movement
produces a downward force at the pick rolls. The friction between the pick roll and the paper
produces a frictional locking condition. If the paper is physically held and not allowed to feed, then the
motor stalls. Slippage between the roll and the paper is theoretically impossible. When the motor is
energized, the pick rolls are driven down into the stack, increasing the normal force and drive force
until the bending strength of the paper is overcome and the paper bends and moves up the dam.
Once this critical threshold is achieved, the normal force remains at a level just high enough to
reliably feed the paper. Rather than having a fixed spring force for feeding all weights of paper like the
D-roll, this device has its own mechanical logic for producing only enough pick energy to feed a single
sheet of paper regardless of its stiffness. High normal force is one of the most significant contributors
to double feeding paper. The pick arm is counterbalanced by an extension spring located on the pick
arm to reduce weight in the rest state. This spring is factory set to exert no more than ten to fifteen
grams on the stack. This is as light as can be realistically set and always guarantee there is some
force to start the autocompensating phenomena. This spring is not to be considered an adjustment
for feeding problems unless it is obvious that the pick arm cannot fall all the way down to the bottom
of the tray or has come loose. Poor gear efficiency can cause the arm to generate higher normal
forces. If the pick assembly is noisy, replacement may be required. The arm must pivot freely through
its full range of motion. On 500-sheet trays there are wrap springs located on the pivot arbors of the
arm. These springs help prevent the arm from bouncing. If the arm appears to be binding or sticky
near the bottom of the tray, these springs may be the problem. Reducing the tension on the
counterbalance spring may be used as a temporary fix to get additional weight at the bottom, until the
pick assembly can be replaced. However, the counterbalance spring is not to be considered an
adjustment for feeding problems.

Autoconnect system, paper tray options, envelope feeder—electrical
Autoconnect cabling and connectors
The printer options make electrical connection automatically, requiring no external cables when the
option is mechanically installed under the printer. Communication between the option and the base
printer stops when you remove an option. The printer no longer recognizes the option and deletes
associated messages. Each installed option below the base printer provides an electrical
autoconnect to the option attached below it. We do not recommend to attach or “Hot Plug” any
options with the base printer power turned on.

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Duplex Option
The duplex option interface is a six pin autoconnector that provides a +24 V dc, +24 V dc return,
serial interface transmit signal, serial interface receive signal, and two ground pins. The duplex option
receives the +24 V dc from the base printer for the duplex motors and also converts the voltage to
+5 V dc for duplex electronics.
Duplex chassis grounding is provided from the printer to the duplex option through a ground spring
attached to the frame and base of the printer. The ground connection is automatically made when the
option is installed below the printer.
The paper input sensor is located in the rear of the duplex option under the input paper guide. The
paper exit sensor is located on the left frame assembly.

Option microcode
The options are “Smart Options” or options that have a system board. The option system board has
a microprocessor that controls the option mechanism. A software architecture is provided that
controls the option and communicates information such as paper path status, sensor status, motor
status, and so on to the base printer.

Paper feed jams

201 Paper Jam

200 Paper Jam

260 Paper Jam

27x Paper Jam
(28x Paper Jam
occurs in the
finisher option only)

250 Paper Jam
23x Paper Jam

202 Paper Jam

24x Paper Jam
23x Paper Jam

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Paper jams—base printer
Error Message 200 Paper Jam - Remove Cartridge
This message indicates that paper is jammed at the printer input sensor. This condition can be
caused by the paper jamming prior to activating the input sensor flag, the sensor not detecting paper
over the sensor, or paper arriving at the sensor too late.
Note: A defective system board or printhead can also cause a 200 Paper Jam message to occur
prior to the paper reaching the input sensor flag. This error can display due to a problem with the
HSYSC signal to or in the printhead. Use the sub error code table to assist in isolating a 200 Paper
Jam message. See “Base printer sub error codes” on page 2-6.
Note: When the StapleSmart finisher option is installed, a secondary message may be displayed
which advises whether or not to remove the job from the finisher. If a job has accumulated in the
finisher, then the printer alternately flashes the primary and secondary messages to indicate that all
accumulated sheets should not be removed during the jam clearance procedure. If the sheets are
removed, then the printer does not reprint these sheets.

Error Message 201 Paper Jam - Remove Cartridge
This message indicates the paper is jammed between the printer input and exit sensors. This
condition can be caused by the paper exiting the input sensor too late or jamming in the fuser
assembly prior to activating the exit sensor flag in time or not at all.
Note: When the StapleSmart finisher option is installed, a secondary message may be displayed
which advises whether or not to remove the job from the finisher. If a job has accumulated in the
finisher, then the printer alternately flashes the primary and secondary messages to indicate that all
accumulated sheets should not be removed during the jam clearance procedure. If the sheets are
removed, then the printer does not reprint these sheets.

Error Message 202 Paper Jam - Open Rear Door
This message indicates the paper is jammed at or near the printer exit sensor located in the fuser
assembly. This can be caused by the paper arriving at the sensor too late, the paper jammed in the
fuser assembly, or jammed exiting the fuser assembly in the redrive assembly, or the exit sensor flag
is not operating correctly. If an output option is installed on the printer, a 202 Paper Jam may be
displayed if the option is not operating properly, especially the pass thru sensor of the output option.
Remove the output options from the printer and check the printer for correct operation. If the printer
operates correctly, then install one output option at a time and check which one fails.
Note: When the StapleSmart Finisher option is installed, a secondary message may be displayed
which advises whether or not to remove the job from the finisher. If a job has accumulated in the
finisher, then the printer alternately flashes the primary and secondary messages to indicate that all
accumulated sheets should not be removed during the jam clearance procedure. If the sheets are
removed, then the printer does not reprint these sheets.

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Paper jams—options
Error Message 23x Paper Jam - Check Duplex Option

231 Paper Jam
Input Sensor
232 Paper Jam
Stage 2
Location

235 Paper Jam
236 Paper Jam
237 Paper Jam

234 Paper Jam
235 Paper Jam
Exit Sensor

Stage 1
Location

Doublefeed Sensor
233 Paper Jam

The paper is most likely jammed in the duplex option, however the paper can also be jammed in the
redrive at the input to the duplex option. The redrive assembly may not be correctly installed or
locked in position or the duplex link is bent and not aligned properly to allow paper to feed correctly
into the duplex option. Use the specific errors below:

• 231 Duplex Paper Jam - Rear–A piece of media did not arrive at the duplex input sensor, but
•
•
•
•
•
•
•
•

did leave the printer exit sensor.
232 Duplex Paper Jam - Rear–A piece of media did not clear the duplex input sensor but did
leave the printer exit sensor.
233 Duplex Paper Jam - Rear–A piece of media failed to make the duplex doublefeed sensor
during turnaround.
234 Duplex Paper Jam - Rear–The media did not reach the duplex exit sensor.
235 Duplex Paper Jam - Front–A piece of media is over the duplex doublefeed sensor.
236 Duplex Paper Jam - Front–A piece of media did not leave the duplex exit sensor.
237 Duplex Paper Jam - Front–A piece of media did not reach the printer input sensor.
238 Duplex Paper Jam–A piece of media is over one of the duplex sensors during a reset.
239 Duplex Paper Jam–A paper jam has occurred in the duplex option.

Note: When the StapleSmart finisher is installed, a secondary message may be displayed which
advises whether or not to remove the job from the finisher. If a job has accumulated in the finisher,
then the printer alternately flashes the primary and secondary messages to indicate that all
accumulated sheets should not be removed during the jam clearance procedure. If the sheets are
removed, then the printer does not reprint these sheets.

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Error Message 24x (x=tray 1 through 5) Paper Jam Check Tray x
The paper has not cleared the pass thru sensor or reached the pass thru sensor of the option above
tray x.
Note: When the StapleSmart Finisher option is installed, a secondary message may be displayed
which advises whether or not to remove the job from the finisher. If a job has accumulated in the
finisher, then the printer alternately flashes the primary and secondary messages to indicate that all
accumulated sheets should not be removed during the jam clearance procedure. If the sheets are
removed, then the printer does not reprint these sheets.

Error Message 250 Paper Jam - Check MP Feeder
The paper is jammed in the multipurpose feeder and has not reached the base machine input sensor
or has not reached the input sensor in time.
Note: When the StapleSmart Finisher option is installed, a secondary message may be displayed
which advises whether or not to remove the job from the finisher. If a job has accumulated in the
finisher, then the printer alternately flashes the primary and secondary messages to indicate that all
accumulated sheets should not be removed during the jam clearance procedure. If the sheets are
removed, then the printer does not reprint these sheets.

Error Message 260 Paper Jam - Check Envelope Feeder
An envelope is jammed in the envelope feeder or has not reached the base machine input sensor.

Error Message 27x Paper Jam - Check Bin x
Paper is jammed in output bin x (x=bin 1 through 3). Generally this message appears when the paper
has not cleared the exit sensor in time, has jammed in the redrive assembly, or has not fed into the
output bin selected.
Note: A 271 paper jam (bin 1) may be displayed when the StapleSmart finisher is installed and a
piece of media is actuating the pass thru sensor of the finisher.

Error Message 28x Paper Jam (x=StapleSmart finisher)
Error Message 280 Paper Jam - Check Finisher
or
Error Message 281 Paper Jam - Check Finisher
When either of these two messages are displayed, they indicate that paper is jammed in the finisher
option. Open the finisher rear door and top cover to remove the jam. Note: If the paper is still
covering the finisher pass thru sensor, then a 271 Error message is displayed. A 281 Paper Jam
message may also be displayed when there is a problem with the stapler assembly or the stapler
card.
Note: When the StapleSmart finisher option is installed, a secondary message may be displayed
which advises whether or not to remove the job from the finisher. If a job has accumulated in the
finisher, then the printer alternately flashes the primary and secondary messages to indicate that all
accumulated sheets should not be removed during the jam clearance procedure. If the sheets are
removed, then the printer does not reprint these sheets.

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Error Message 282 - Check Stapler
This message indicates that a staple jam has been detected during normal operation, when printing
and stapling jobs. The printer alternately flashes the primary and secondary message to indicate that
all accumulated sheets should be removed during the jam clearance procedure.

Error Message 283 - Check Stapler
This message indicates that a staple jam has been detected during a stapler priming operation.
There is no secondary message displayed.
Note: After the error has been cleared, the printer does not reprint any pages which existed in the
accumulator for stapling.
Note: Do not use the Sub Error chart to help diagnose problems when 281, 282, and 283 are
displayed.

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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 instructions below in addition to all the usual
precautions, such as turning off power before removing logic boards:

• Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until you are
ready to install the part into the machine.

• Make the least-possible movements with your body to prevent an increase of static electricity
•
•
•
•
•
•
•

from clothing fibers, carpets, and furniture.
Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This
discharges any static electricity in your body to the machine.
Hold the ESD-sensitive part by its edge connector shroud (cover); do not touch its pins. If you
are removing a pluggable module, use the correct tool.
Do not place the ESD-sensitive part on the machine cover or on a metal table; if you need to put
down the ESD-sensitive part for any reason, first put it into its special bag.
Machine covers and metal tables are electrical grounds. They increase the risk of damage
because they make a discharge path from your body through the ESD-sensitive part. (Large
metal objects can be discharge paths without being grounded.)
Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install
machine covers when you are not working on the machine, and do not put unprotected
ESD-sensitive parts on a table.
If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case).
Be extra careful in working with ESD-sensitive parts when cold-weather heating is used
because low humidity increases static electricity.

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Adjustment procedures
Duplex motor drive belt adjustment
Do the duplex motor belt and drive belt adjustment whenever you remove or replace the duplex
motor or loosen the motor or drive belt idler pulley.
Service tip: Excessive belt tension can result in stalling the duplex motor. Too little belt tension can
result in belt slippage.
To do the duplex drive belt adjustment:

1. Do the removal procedure “Duplex front cover door removal” on page 4-19 to access the
2.
3.
4.

drive belt idler pulley.
Loosen the idler pulley mounting screw and position the idler to provide 3 mm (±.5 mm) drive
belt deflection.
Tighten the idler pulley mounting screw being careful to maintain the adjustment.
Reassemble the Duplex Option.

To do the duplex motor belt adjustment:

1. Do the removal procedure “Duplex motor removal” on page 4-19 to access the motor
mounting screws but do not remove the motor.

2. Loosen the screw in the elongated adjustment slot and position the motor to provide 3 mm (±.5
3.
4.

mm) motor belt deflection.
Tighten both mounting screws being careful to maintain the adjustment.
Reassemble the Duplex Option.

Fuser solenoid adjustment
Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser
solenoid while installed in the printer. Adjust the screw on the eccentric mounted on the solenoid
housing to provide an air gap between the rear of the solenoid stator and the solenoid armature. The
solenoid air gap for all models is 4.5 mm ± 0.1 mm.

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Gap adjustment
The gap adjustment allows you to increase the minimum gap between sheets of paper as they are
fed through the printer. This adjustment reduces the printer overall performance, such as pages per
minute, but can help in reducing the amount of curl of some printed medias, thus improving media
stacking in the output bin.

1.
2.
3.
4.

Enter the Diagnostic Mode.
Select Ep Setup from the Diagnostic Menu.
Select Gap Adjust.
The range of the GAP adjustment is 0 to 255. Adjust the gap setting by using Menu to select the
value. If GAP=0 displays, it indicates a factory setting to minimum gap. Select a value and run
several copies of the media that displays a curl problem. It may take several tries before
improvement is noticed.

Note: This setting has no effect when duplexing.

Printhead assembly adjustment
Do the printhead assembly adjustment whenever you remove or replace the printhead assembly or
loosen the mounting screws.
Install the new printhead with the three mounting screws centered in the slots in the printhead frame
assembly. Leave the screws loose enough to allow the printhead assembly to move from side to side
within the slots. It is necessary to perform a registration adjustment before locking down the three
printhead mounting screws.
To perform the registration adjustment:

1.
2.
3.
4.
5.

6.

7.

Turn the printer off.
Press and hold Return and Go.
Turn the printer on and release the buttons when “Performing Self Test” displays.
Select Registration from the menu.
Select Quick Test Page. The test page should only be printed on letter or A4 paper from
Tray 1. The Quick Test Page consists of alignment diamonds, horizontal lines that can be used
for skew adjustment, page count setting, printer serial number code levels, and print registration
settings.
Check the Quick Test Page for any sign of skew by checking the diamonds at the top left and
top right of the test page for equal distance from the top of the page. If necessary, adjust the left
or right printhead mounting screws and check the skew again by running another Quick Test
Page. This procedure may take two or three attempts before you get satisfactory results.
When you have the correct adjustment, gently tighten the printhead mounting screws being
careful not to move the printhead assembly.

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Paper alignment assembly adjustment
Do the alignment assembly adjustment whenever you replace the alignment assembly. Always print
a copy of the Quick Test Page before making any adjustments to the alignment assembly reference
adjustment screw. When replacing the alignment assembly, it is necessary to back the reference
adjustment screw out far enough to remove the old assembly and install the new one.

• If you are replacing the alignment assembly go to step A.
• If you are only adjusting the reference adjustment screw go to step B.
Step A
Print a copy of the Quick Test Page and check the margin adjustments printed on the test page.
These settings should be within the range specified in “Print registration” on page 3-16.
Do the reference adjustment if you are sure the margins are set correctly.

1. Loosen the locknut on the inside rear of the alignment assembly.
2. Remove the two screws holding the alignment assembly to the left side frame.
3. Back the reference adjustment screw out far enough to allow the alignment assembly to be
4.

removed from the printer. It is not necessary to completely remove the screw.
Install the new alignment assembly. Turn the reference screw clockwise with a 7 mm nut driver
until it touches the back of the reference plate and tighten the nut with a 5.5 mm wrench.

The reference adjustment screw can be adjusted without loosening the nut. Turn the screw clockwise
a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin.
Continue adjusting the screw as you check the results of each adjustment on a new test page until
you obtain the results you want.

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Step B
Print a copy of the Quick Test Page and check the margin adjustments printed on the test page.
These settings should be within the range specified in “Print registration” on page 3-16. The
reference screw can be adjusted without loosening the locknut. Turn the screw a few turns and print
a copy of the Quick Test Page as you check the diamonds on the left margin. Continue adjusting the
screw as you check the results of each adjustment on a new test page until you obtain the results
you want.

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Screw identification table
The following table contains screw types, locations, and quantities necessary to service the printer.
Each screw callout in the removal procedure graphic displays the screw reference number listed in
the table. Pay careful attention to each screw type location when doing removals. You must install
the correct screw type in each location during reassembly.
Reference
number

Screw type

Location

Purpose

Qty

M3.5x8 mm Thread
Cutting

right side frame to center pan

attach

1

toner level sensor

mounting

1

charge roll bracket

mounting

1

main drive gearbox

mounting

3

EP module to left and right side frame

attach

9

developer drive assembly

mounting

2

stacker duct to frame

mounting

2

cartridge hold down assembly

mounting

2

MPT deflector

mounting

2

laser cover

mounting

4

deflector

mounting

2

spring

mounting

1

system board

mounting
(front)

2

integrated tray (ITC) board

mounting

1

stacker support to right side frame

attach

2

paper alignment assembly

mounting

2

toner cartridge guide track

mounting

2

left side frame to center pan

attach

3

right side frame to center pan

attach

2

deflector

mounting

2

INA cover
(2 screws per cover)

attach

6

M3.5x12 mm
Thread Cutting

M3x5 mm Taptite

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Reference
number

Screw type

Location

Purpose

Qty

M3x6 mm Taptite

outer shield

mounting

6

inner redrive deflector

mounting

2

interconnect board to center pan

mounting

2

system board to interconnect board ground

attach

2

system board to inner shield

mounting

2

system board (back)

mounting

2

lower stacker duct

mounting

1

ground cables to ground (center pan–front)

attach

1

cable clip (main drive gearbox, BTM)

mounting

2

LVPS

mounting

2

autocompensator hanger bracket

mounting

1

stacker duct

mounting

1

system board to shield

mounting

2

system board

mounting

2

shield ground

attach

1

LVPS

mounting

2

fuser cover

mounting

2

cable clip

mounting

2

outer shield

mounting

6

INA cover

mounting

1

HVPS board

mounting

2

M3x8 mm Taptite

M3x6 mm Taptite
Panhead

M3x12 mm Taptite
Panhead

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Reference
number

Screw type

Location

Purpose

Qty

M3x28 mm Taptite
Panhead

developer drive ground (bottom hole)

attach

1

M3.5x8 mm Plastite
Thread Forming

autocompensator

mounting

3

M3.5x10 mm
Plastite Thread
Forming

right side cover

mounting

1

right side frame to pan

attach

3

left side frame to pan

attach

1

right side frame to right side cover

attach

1

printhead to EP frame

mounting

3

M3.5x12 mm
Plastite Thread
Forming with
washer

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Removal procedures
CAUTION:Remove the power cord from the printer or wall outlet before you connect or
disconnect any cable or electronic board or assembly for personal safety and to prevent
damage to the printer. Use the handholds on the side of the printer. Make sure your
fingers are not under the printer when you lift or set the printer down.
Note: Some removal procedures require removing cable ties. You must replace cable ties during
reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.

Covers removals
Left door removal
1. Open the upper and bottom front covers.
2. Press the two left door latch buttons (A) and open the left door.

A

3. Release the left door from the rear hinges and remove the door.

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Right cover removal
1.
2.
3.
4.
5.

Remove the redrive cap
Remove the redrive assembly.
Open the upper and lower front covers.
Remove the print cartridge.
Remove the right cover mounting screw (A) and release the cover latch (B).

A(324)

6. Remove the right side cover mounting screw (C).

C(324)

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7. Remove the right side cover.

Cover retainers
Note: When replacing the right side cover, make sure the cover retainers are correctly located in the
appropriate slots in the right side frame.

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Upper front cover removal
1. Raise the upper front cover.
2. Remove the upper front cover mounting screws (A).

A(323)

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3. While holding the two upper front cover latches, lift off the cover.
Note: When removing the cover, hold the upper and lower latch and spring to prevent them
from falling into the printer.

Note: Use caution to avoid scratching or damaging the operator panel lens cover.

4. Set aside the operator panel overlay.
Note: Be sure to replace the overlay when you replace the upper front cover.

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Laser cover removal
1.
2.
3.
4.
5.
6.

Remove the left door.
Remove the right cover. See “Right cover removal” on page 4-10.
Remove the paper support.
Remove the redrive cap.
Press the fuser wiper cover latch and remove the cover.
Loosen screw (A) and remove the two screws (B) on the right side.

B(102)

A(323)

7. Remove the mounting screws (C) from the left side.

C(102)

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8. Remove the paper bin full sensor flag assembly from the mounting bracket. See “Paper bin full
sensor flag assembly removal” on page 4-54.

9. Unlatch the front right and front cover posts (left) and remove cover.

10. Remove fan grill cover.

Note: Be sure to reseat the fan grill cover before replacing the laser assembly cover.

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Bevel gear removal
1.
2.
3.
4.

Open the left door.
Remove the inner shield.
Remove the gear guard.
Remove the power takeoff shaft and spring (A) through the bottom of the printer.

A

5. Place your thumb on the top of the gear and press firmly down and away.
Note: You need to exert firm pressure to snap the bevel gear out.

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Installation
1. Remove any washer that may be present (A) and discard.
2. Lubricate areas (A) that engage the journal (B) with grease, from the provided packet.
3. Place the new washer (C) on the bevel gear shaft.

4. Insert the bottom portion and press or pull into position.
Note: You should hear two distinct snaps. If you only hear one, the bevel gear is only partially
engaged and you should continue to press until the second snap is heard. Very firm pressure is
required.
CAUTION: Do not brace your hands below the bevel gear itself. When the gear double-snaps
into place, it may pinch your hand.

5. Install the power takeoff shaft and spring.
6. Install the gear guard.
7. Install the inner shield.

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Communications board removal
1. Remove the outer shield. See “Outer shield removal” on page 4-52.
2. Remove features and options from the interconnect board only if they block access.
Warning: Observe all ESD precautions while handling ESD-sensitive parts. See “Handling
ESD-sensitive parts” on page 4-1.

3. Remove the communications board mounting screw (A).

B(201)

C

A(232)

4. Remove the communications board shield mounting screw (B).
5. The communications board is held in place by a ground clip (C) on the shield that attaches the
communications board shield to the side frame. Pull the board up to unclip the shield.

6. Remove the screws that hold the shield to the communications board.
Note: Retain the shield and screws to install on the new board.

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Cover closed switch/cable removal
Note: Pay careful attention to the cable routing through the printer before you remove the cover
closed switch and cable assembly.

1. Remove the left cover, upper front cover, and outer system board shield.
2. Disconnect the cover closed switch cable from the system board (J3).
3. Remove the screw (A) that attaches the cover closed switch.

A

4. Remove the cable retainer from the left side of the upper front cover hinge assembly.
Note the routing of the cover closed switch and operator panel cables.

5. Remove the cover closed switch/cable assembly.

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Developer drive assembly removal
1. Remove the inner shield. See “Inner shield removal” on page 4-34.
2. Remove the developer drive assembly mounting screws (A).
3. Remove the developer drive assembly.
Note: Be sure the developer drive shaft and coupler aligns with the hub on the main drive assembly
when reinstalling the assembly.

Frames removals
EP frame assembly
1. Remove the left and right side frames. See “Left side frame” on page 4-20 and “Right side
2.

frame” on page 4-22.
Remove the EP frame assembly.

Left side frame
1.
2.
3.
4.
5.

Remove the covers.
Remove the inner shield. See “Inner shield removal” on page 4-34.
Remove the main drive assembly. See “Main drive assembly removal” on page 4-44.
Remove the upper front cover hinge assembly. See “Upper front cover hinge assembly
removal” on page 4-62.
Remove the multipurpose tray/lower deflector assembly.

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6. Remove the paper alignment assembly. See “Paper alignment assembly removal” on
7.

page 4-52.
Remove the left side frame mounting screws (A).

A(102)

8. Place the printer on its back and remove the left side frame mounting screws (B).

B(104)

9. Remove the left side frame.

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Right side frame
CAUTION: Unplug the printer before you begin.

1.
2.
3.
4.
5.
6.
7.
8.

Remove the right side cover. See “Right cover removal” on page 4-10.
Remove the laser cover. See “Laser cover removal” on page 4-14.
Remove the LVPS. See “Low voltage power supply removal” on page 4-42.
Remove the multipurpose tray assembly.
Disconnect the autocompensator arm bias spring from the right side frame.
Remove the toner sensor mounting screw (A), disconnect the sensor cable and remove the
toner sensor.
Remove the smart cartridge contact assembly mounting screw (C)
Remove the right side frame mounting screws (B) and remove the right side frame.

B(102)

A(102)

C

B(102)

CAUTION: Be sure the fuser assembly has cooled before working on any of the fuser FRUs.

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Fuser assembly removal
CAUTION: Unplug the printer before you begin.

1. Remove the redrive assembly. See “Redrive assembly removal” on page 4-57.
2. Remove the fuser mounting screws (A).

A

A

3. Disconnect the AC fuser lamp cable (C) from the fuser lamp connector (D).
4. Pull the fuser assembly out far enough to remove the fuser lamp cable.
5. Disconnect the DC fuser cable (E) from the fuser board.

D

C

E

6. Pull the cables free and remove the fuser.

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Installation
1. When you reinstall the fuser, be sure to route the fuser lamp cable through the channel (F) on
the right side frame above the LVPS, under the clip (G), and through the notch in the frame (H)

F

G

H

2. Route the fuser lamp cable through the opening in the fuser as shown (J).

J

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Fuser cover removal
CAUTION: Unplug the printer before you begin.

1. Remove the fuser assembly. See “Fuser assembly removal” on page 4-23.
2. Note the thermistor cable (A) routing.

A

3. Clip the cable tie (B) and disconnect the thermistor cable (C) from the fuser board.

C

B

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4. Disconnect the AC fuser lamp cable (A) from the top left side of the fuser cover.

A

5. Remove the two screws (C) from the right side fuser lamp contact cover.
6. Release the latch (D) and remove the cover.

D

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C(202)

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7. Remove screw (A) that attaches the fuser lamp contact to the fuser cover.

B

A

8. Remove the two screws (B), one on each side of the fuser, that attach the fuser upper cover
assembly to the fuser frame.

9. Remove the fuser laser cover.

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Fuser exit sensor or fuser narrow media sensor removal
1. Remove the fuser. See “Fuser assembly removal” on page 4-23.
2. Cut the cable tie (A).

Narrow Media Sensor

A

Exit Sensor

3. Unplug the sensor from the fuser control board.
4. Remove the sensor from the lower exit guide assembly.

Fuser lamp removal
1. Remove the fuser assembly. See “Fuser assembly removal” on page 4-23.
2. Disconnect the fuser lamp AC cable from the left side of the top cover assembly.
3. Remove the two screws (A) from the left side fuser lamp contact cover.
Warning: Take care when removing the screw, as the lamp is under spring tension. When the
contact is released, damage to the lamp or contact may occur.

A(202)

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4. Remove the left lamp contact assembly.
5. Remove the fuser lamp.
Warning: The lamp is under spring tension and care must be used when removing the lamp
from the fuser. Grip the lamp by the ceramic end piece and remove it from the fuser
assembly. Be careful not to touch the glass as skin oils and acids can reduce the life
of the lamp.

Use the following table to identify and install the correct lamp.
Description

P/N

Fuser Lamp 115 V

56P1362

Fuser Lamp 220 V

56P1363

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Fuser transfer plate removal
1. Remove the upper paper deflector. See “Upper paper deflector assembly removal” on
page 4-63.

2. Remove the transfer roll.
3. Remove the inner paper deflector. See “Inner paper deflector assembly removal” on
page 4-33.

4. Lift the left side of the fuser transfer plate (A) and move the plate to the left to clear the right side
from its mounting.

A
5. Remove the screw that attaches the transfer plate ground wire to the center pan.
6. Remove the fuser transfer plate.
7. Remove the screw that attaches the deflector cable to the transfer plate.

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High voltage power supply removal
CAUTION: There is a danger from hazardous voltage in the area of the printer where you
are working. Unplug the printer before you begin, or use caution if the printer must receive
power in order to perform the task.

1. Remove the inner paper deflector. See “Inner paper deflector assembly removal” on
2.
3.

page 4-33.
Remove the right side cover. See “Right cover removal” on page 4-10.
Disconnect the HVPS cable from the HVPS at connector (A).

A
4. Disconnect the transfer roll cable (B) from the HVPS board.
Warning: Use care when disconnecting the cable from the transformer on the HVPS. The
cable and connector can be easily damaged.

B

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5. Remove the HVPS mounting screws (C).

C(235)

6. Slide the HVPS to the left to release the mounting tab from the center pan and remove the
HVPS.

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Inner paper deflector assembly removal
1. Remove the paper tray.
2. Remove the upper paper deflector assembly. See “Upper paper deflector assembly
3.
4.
5.

removal” on page 4-63.
Place the printer on its side.
Remove the MPT deflector assembly. See “Inner paper deflector assembly removal” on
page 4-33.
Gently pry the inner paper deflector from the left and right mounting posts (A) located on the
bottom of the printer and remove the deflector.

A

6. Disengage the two latches (B) on the upper part of the deflector from the upper edge of the
frame (C) and lift to remove.

C

B

C

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Inner shield removal
1. Remove the left door.
2. Remove the outer system board shield. See“Outer shield removal” on page 4-52.
3. Remove all features or option boards from the interconnect board.
Warning: Observe all ESD precautions while handling ESD-sensitive parts. See “Handling
ESD-sensitive parts” on page 4-1.

4.
5.
6.
7.

Disconnect all cables from the system board.
Remove the inner shield mounting screws (A).
Remove the USB connector mounting screw (B), if present.
Remove the inner shield.

B

A

Input sensor removal
1. Remove the inner paper deflector assembly.
2. Disconnect the input sensor cable from the input sensor.
3. Release the input sensor from its mounting and remove.

4-34 Service Manual

A

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Integrated tray autocompensator assembly removal
1.
2.
3.
4.
5.

Remove the paper tray.
Remove the left door.
Remove the outer shield. See “Outer shield removal” on page 4-52.
Disconnect the autocompensator motor cable from the system board (J28).
Cut cable tie (A) on left side.

A

6. Place the printer on its back.

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7. Locate the integrated tray autocompensator assembly (A) on the bottom of the printer and
disconnect the autocompensator arm bias spring (B).
Note: When you remove the spring, note the larger loop attaches to the side frame.

8. Remove the C-clip (C) that rests against the right side frame from the autocompensator pivot
shaft.

A

4-36 Service Manual

C

B

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9. Disconnect the autocompensator sensor cable (D) from the assembly.
10. Remove the autocompensator assembly mounting screw (E).

D

E

11. Remove the integrated tray autocompensator assembly.
Note: When you reinstall the assembly, reinstall the cable tie.

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Integrated tray autocompensator pick roll assembly removal
1. Remove the integrated tray and look underneath the printer for the autocompensator arm. Pull
the arm down.

2. Press on the end of the tab and pull the pick roll off the arm. Repeat this step for the pick roll on
the other side. Next, gently release the autocompensator arm. Discard the used pick rolls.

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Installation
1. Remove the new pick rolls from their packaging.
2. Pull the autocompensator arm down. Locate the recessed area on the pick roll and align it with
the tab on the arm. There are two arrows on each pick roll. Make sure the bottom arrow faces
you as you align the recessed area with the tab.

3. Push the pick roll onto the arm with the tab aligned. Repeat this step on the other side to install
the other pick roll.

4. Gently release the autocompensator arm. Insert integrated tray.

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Interconnect board assembly removal
CAUTION: Unplug the printer before you begin.

Warning: Observe all ESD precautions while handling ESD-sensitive parts. See “Handling ESDsensitive parts” on page 4-1.
Note: Any time the interconnect board assembly is replaced, the Configuration ID must be reset in
NVRAM on the new interconnect board. Go to “Setting configuration ID” on page 3-18.

1. Remove any feature or option cards from the interconnect board.
2. Remove the inner shield. See “Inner shield removal” on page 4-34.
3. Remove the LVPS access plate and disconnect the LVPS cable from CN2 (A).

A

4. Disconnect cables J4 and J5 from the interconnect board.

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5. Place the printer on its side and remove the mounting screws (A).

A(202)

6. Remove the interconnect board assembly.

Internal tray card (ITC)/Paper size sensing board removal
1. Remove the paper size sensing board mounting screw (A).

C

A

B

2. Disconnect the paper size sensing board cable (B) from the board.
3. Remove the paper size sensing board from the ITC latch (C).
4. Remove the paper size sensing board.

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Low voltage power supply removal
CAUTION: Unplug the printer before you begin.

1. Remove the right side cover. See “Right cover removal” on page 4-10.
2. Remove fuser assembly. See “Fuser assembly removal” on page 4-23.
3. Remove the LVPS mounting screws (A) from the rear of the bottom pan.

A(203)

4. Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser
lamp cable.
Warning: The LVPS assembly may be difficult to remove from the printer. Do not use
excessive force in the removal.

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5. Remove the LVPS access plate.
6. Disconnect the interconnect card cable from the LVPS (A).

A

7. Remove the LVPS.

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Main drive assembly removal
1. Remove the inner shield. See “Inner shield removal” on page 4-34.
2. Remove the gear guard (A).

A

3. Remove the developer drive assembly. See “Developer drive assembly removal” on
page 4-20.

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4.
5.
6.
7.

Remove the power takeoff shaft and spring (A) through the bottom of the printer.
Remove all cables from the cable clamps (B) on the main drive assembly.
Remove the ground cable screw (C).
Remove the main drive assembly mounting screws (D).

8. Remove the link from the rear of the main drive assembly.
9. Disconnect the cable from the main drive motor.
10. Remove the main drive assembly.
Note: Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when
reinstalling the main drive assembly.
Warning: Whenever the main drive assembly is removed from the printer it must be handled very
carefully. Do not allow any of the gears to come in contact with any metal or other hard
surface to avoid gear damage. It is also very important not to let any dirt, paper, staples,
or other material come in contact with the grease in the gears.

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Main fan removal
1. Remove the laser cover. See “Laser cover removal” on page 4-14.
2. Remove the inner shield. See “Inner shield removal” on page 4-34.
3. Remove the fan grill cover.

4. Note the routing of the main fan cable (A) and disconnect the cable from the system board at
connector J7.

B

A

B

5. Release the four latches (B) and remove the fan from the left side frame.

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Multipurpose tray/lower deflector assembly removal
1. Open the multipurpose tray to a position that allows the left and right tray hinge slots (A) to align
with the rectangular mounting posts (B). Pull upward on each tray hinge to remove the tray from
the two mounting posts.
Warning: Be careful not to break the hinges.

B

A

2. Remove the upper paper deflector. See “Upper paper deflector assembly removal” on
3.
4.
5.

page 4-63.
Remove the solenoid mounting screw (C).
Remove the screws (D) mounting the multipurpose tray/lower deflector assembly.
Remove the multipurpose tray/lower deflector assembly.

D(102)

C(102)

D(104)

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Operator panel assembly removal
1. Remove the upper front cover.
2. Remove the operator panel overlay (A) and set it aside.
A

3. Gently press the operator panel lens tabs to loosen the operator panel.

4. Disconnect the operator panel cable and remove the operator panel.

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Operator panel bezel removal
1. Remove the upper front cover. See “Upper front cover removal” on page 4-12.
2. With the upper front cover upside down on a soft, non-scratching surface, release the clips and
remove the operator panel lens cover.
Note: Use caution to avoid scratching or damaging the operator panel lens cover.

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Operator panel cable removal
Note: Pay careful attention to the cable routing through the printer before you remove the operator
panel cable.

1.
2.
3.
4.
5.
6.

Remove the left cover. See “Left door removal” on page 4-9.
Remove the upper front cover. See “Upper front cover removal” on page 4-12.
Remove the outer system board shield. See “Outer shield removal” on page 4-52.
Disconnect the operator panel cable from connector J15 on the system board.
Remove the operator panel. See “Operator panel assembly removal” on page 4-48.
Remove the cable retainer from the left side of the upper front cover hinge assembly.
Note the routing of the operator panel and cover closed switch cables.

7. Remove the old cable from the printer.
8. Plug the new operator panel cable into the operator panel.
9. Snap the operator panel into the upper front cover.

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Optional 250 or 500-sheet paper tray assembly removal
Note: Remove the printer and other paper feed options to access the failing optional paper tray
assembly.

Paper tray autocompensator assembly removal
1.
2.
3.
4.

Remove the printer and other paper feed options.
Disconnect the autocompensator assembly bias spring from the tray frame.
Disconnect the autocompensator assembly motor cable.
Remove the three autocompensator assembly mounting screws and remove the compensator
assembly.

Paper tray frame assembly removal
1. Remove the autocompensator assembly.
2. Release the paper pass thru sensor from its retaining tabs.
3. Release the frame assembly from the front and rear retaining tabs and remove the paper tray
frame assembly.

Paper tray board removal
1. Remove the paper tray frame assembly.
2. Disconnect all cables from the paper tray board.
3. Remove the three paper tray board mounting screws and remove the board.
Note: Reinstall with the paper out sensor flag positioned in the sensor slot on the paper tray board.

Paper tray paper out sensor flag removal
1. Remove the paper tray frame assembly.
2. Remove the paper tray board.
3. Remove the paper out sensor flag.
Paper size spring comb removal
1. Remove the paper tray board.
2. Remove the paper size spring comb mounting screw and remove the spring comb.

Repair information

4-51

4060-xxx

Outer shield removal
1. Remove the left door. See “Left door removal” on page 4-9.
2. Loosen the outer shield mounting screws (A) and remove the shield.
A(202)

A(202)

Paper alignment assembly removal
1. Remove the upper paper deflector assembly. See “Upper paper deflector assembly
removal” on page 4-63.

2. Remove the inner paper deflector assembly. See “Inner paper deflector assembly removal”
3.
4.

on page 4-33.
Release the input paper sensor from its mounting and remove.
Remove the left door.

4-52 Service Manual

4060-xxx

5. Remove the paper alignment assembly mounting screws (A).

6. Locate the paper alignment assembly reference adjustment screw (B) through the left frame and
remove the screw.

B

7. Remove the paper alignment assembly.
Note: Do the “Paper alignment assembly adjustment” on page 4-4 when you reinstall the
assembly.

Repair information

4-53

4060-xxx

Paper bin full sensor flag assembly removal
1.
2.
3.
4.
5.

Remove the left door.
Remove the right cover.
Remove the rear paper deflector.
Press the fuser wiper cover latch and remove the cover.
Loosen screw (A) and remove the two screws (B) on the left side.

B(102)

A(323)

6. Remove the mounting screws (C) from the right side.

C(102)

4-54 Service Manual

4060-xxx

7. Lift the right corner of the laser assembly cover to access the flag.

8. Use your thumb to bend the paper full flag assembly slightly to unlatch it from the mounting
bracket.

Pick roll removal (MPT)
1. Remove the upper paper deflector. See “Upper paper deflector assembly removal” on
2.

page 4-63.
Release the pick roll retaining tab and slide the pick roll off the shaft.

Repair information

4-55

4060-xxx

Printhead removal
1. Remove the laser assembly cover. See “Laser cover removal” on page 4-14.
2. Disconnect the printhead cables (A) from the printhead assembly.
3. Remove the printhead mounting screws (B) and remove the printhead.
Note: Do the “Printhead assembly adjustment” on page 4-3 whenever you remove or replace
the printhead assembly or loosen the mounting screws.

A

B(425)

A

Note: The 000/010 machine type printhead is shown. Cables for the 200/210 and for the 400/410
machine type are different. See “Printhead 1 (000/010)” on page 7-10, “Printhead 2 (200/210)” on
page 7-11, and “Printhead 3 (400/410)” on page 7-12.

4-56 Service Manual

4060-xxx

Redrive assembly removal
1.
2.
3.
4.

Remove the redrive door assembly.
Remove the redrive exit cover.
Remove the redrive assembly mounting screws (A).
Release the redrive assembly mounting latches (B) and remove the redrive assembly.

Repair information

4-57

4060-xxx

Smart contact assembly removal
1.
2.
3.
4.
5.
6.

Remove the print cartridge.
Remove the left side door. See “Left door removal” on page 4-9.
Remove outer system board shield. See “Outer shield removal” on page 4-52.
Disconnect smart cartridge cable from connector J19 on the system board.
Remove smart cartridge contact assembly mounting screw (B).
Note the routing of the smart cartridge contact assembly cable (C).
Remove the assembly (A).

Note: Be sure to route the cable in the same location, as shown (C), when replacing the assembly.

System board removal
Warning: Observe all ESD precautions while handling ESD-sensitive parts. See “Handling ESDsensitive parts” on page 4-1.

1. Remove the outer shield. See “Outer shield removal” on page 4-52.
2. Disconnect all cables from the system board.
3. Remove all features and options from the interconnect board.

4-58 Service Manual

4060-xxx

4. Remove the five system board mounting screws (A).
5. Remove the USB screw (B)

A(232)

B

A(102)

6. Remove the system board.
7. Remove the communications board mounting screw (C).

D(201)

E

C(232)

8. Remove the communications board shield mounting screw (D).
9. The communications board is held in place by a ground clip (E) that attaches the
communications board shield to the side frame. Pull the board up to unclip the shield.

10. For the non-network system board, remove the two screws that hold the shield to the
communications board.
Note: Retain the shield and any screws to install on the new board.

Repair information

4-59

4060-xxx

System board installation
Note: The replacement system board assembly contains a communications board connected to the
system board. To install, you need to separate the boards.
Warning: Observe all ESD precautions while handling ESD-sensitive parts. See “Handling ESDsensitive parts” on page 4-1.

1. Flex the communications board to separate the boards.

2. For non-network models, connect the communications board bracket to the communication
board with two screws (A).

A

3. Clip the communications board shield ground clip on the frame and insert the communications
4.
5.
6.
7.
8.
9.

card into the interconnect card slot.
Replace the communications board shield mounting screw to connect the bracket to the frame.
Insert the communications board mounting screw.
Install the system board.
Insert the USB screw.
Replace the five mounting screws.
Replace the features/options and reconnect all cables.

4-60 Service Manual

4060-xxx

Toner sensor removal
1. Remove the right side cover. See “Right cover removal” on page 4-10.
2. Remove the toner sensor mounting screw (A).
3. Disconnect the toner sensor cable and remove the toner sensor.

A(102)

Transfer roll assembly removal
1. Open the upper front cover and remove the print cartridge.
2. Unsnap the transfer roll assembly from the left pivot arm.
3. Lift the transfer roll assembly toward the left and remove it from the printer.

Repair information

4-61

4060-xxx

Upper front cover hinge assembly removal
1. Remove the upper front cover. See “Upper front cover removal” on page 4-12.
2. Remove the laser cover assembly. See “Laser cover removal” on page 4-14.
3. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins and
remove the pins. Note the pin orientation and the C-clip location on the inside of each hinge.

A

B

A

4. Detach the two springs (B) from the upper front cover hinges.
5. Detach spring (C) from the left side of the hinge assembly.
6. Remove the cover closed switch assembly.

C

D

B

A

B

7. Disconnect the operator panel cable from the operator panel assembly.
8. Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from
the mounting bracket (D).

9. Lift the left pivot arm from the bracket and move the upper cover hinge assembly toward the left
10.

to clear the right upper cover pivot arm from the mounting bracket.
Remove the upper front cover hinge assembly.

4-62 Service Manual

4060-xxx

Upper paper deflector assembly removal
1. Open the multipurpose tray and remove the tray from the two mounting posts.
2. Gently release the upper deflector assembly latch from its mounting on the right side frame and
3.

slide to the right.
Remove the upper deflector assembly.

Repair information

4-63

4060-xxx

4-64 Service Manual

4060-xxx

5. Connector locations
Autoconnect
Connector

Pin no.

Bottom autoconnect
3

2

1

Front autoconnect
3

2

1

Top autoconnect
1

2

8

3

7

+24 V dc

2

0 V dc

3

+5 V dc

4

0 V dc

5

0 V dc

6

0 V dc

1

0 V dc

2

0 V dc

3

0 V dc

4

+5 V dc

5

0 V dc

6

+24 V dc

1

0 V dc

2

+5 V dc

3

0 V dc

4

0 V dc

5

0 V dc

6

+5 V dc

7

0 V dc

8

+24 V dc

4

5

6

1

4

5

6

Signal (static)

4

6

5

Connector locations

5-1

4060-xxx

Envelope feeder board
Connector

Pin no.

J2

1

J4

1

J1

J2

J3

N/A

2

Ground

3

Tx (EOC)

4

Ground

5

Rx (EOC)

6

+24 V dc Return

7

+24 V dc

1

Ground

2

Paper Present

3

+5 V dc

1

Ground

2

Paper Present

3

+5 V dc

1

Motor - Phase B-

2

Motor - Phase A-

3

Motor - Phase B+

4

Motor - Phase A+

J1

1

J3

1

1

J4

Signal

Fuser Board
Fuser Board (not a FRU)

Connectors
J1–System board
J2–Narrow media sensor

1

1

J3–N/A

J2

J4–Solenoid

J4
1
J1

5-2

Service Manual

J5–Exit sensor

1
J6

J5
1

J6–Thermistor

4060-xxx

High-capacity output stacker board
Connector

Pin no.

J1A
Autoconnect

1

+24 V dc

2

Ground

3

+5 V dc

1

Prtxdin

2

Ground

3

prtrxd

4

Ground

5

N/C

1

+24 V dc

2

Ground

3

+5 V dc

1

prtxdout

2

Ground

3

prtrxd

4

Ground

1

Ground

2

Paper Present

3

RVsnsr

1

mtrout1

2

mtrout2

3

Ground

4

Ground

5

tach +

6

+5 V dc

1

Ground

2

Ground

3

binful

4

binful

5

RVsnsr

1

Upper unit

2

Upper/Lower Unit

3

Lower Unit

J1B

1

J2A
Autoconnect

J6
S

M

J2B

J3 Pass thru
sensor

J4 DC motor

J5 Bin full/near
full dual sensor

J6 connector jumper locations
High-capacity
stacker board

Pin 1

Pin 2

Pin 3

Upper unit board

X

X

Not used

Lower unit board

Not used

X

X

J6 Jumper
connector

Signal

Connector locations

5-3

4060-xxx

High voltage power supply
Connector

CN no.

JC9 Dr.B
JC10

JC5 Dev
JC6
JC7 TAR
JC8

JC3 PCD
JC4

T302

JC1 Chg
JC2

CN1 System board

1

5-4

Service Manual

CN1

Signal

1

Developer PWM

2

+24 V dc Return

3

Charge PWM

4

+24 V dc IN

5

TX PWM

6

TX Enable

7

TX CUR PWM

8

SVRO OUT

4060-xxx

Interconnect board
Connector

200/210/400/410

1

4
J2

1

J4
+24V

1

N/A

J2 LVPS

1

+42 V dc

2

Heaton

3

Xeroxing

4

+24 V dc

5

+24 V dc

6

+24 V dc

7

Ground

8

Ground

9

Ground

1

J1

J5

F1

+5V

F2

J7
J11

10

Ground

1

Ground

2

Ground

3

Ground

4

Ground

5

+5 V dc

6

+5 V dc

7

+5 V dc

8

+5 V dc

1

0 V dc

2

+5 V dc

3

0 V dc

4

+24 V dc

1

+24 V dc

2

Ground

J6 Autoconnect
BTM/FNT

1

+24 V dc

2

Ground

J7 System
board

1

N/A

J11 Feature/
option

1

N/A

J12 Feature/
option

1

N/A

J3 LVPS

J12

000/010

J4 Autoconnect
4
1
BAR CODE AREA

J2

1

J4

J5

+24V F1

J7

U3

1

J3

+5V

J1

1

F2

Signal

J1 System
board (comm
board)

J3

BAR CODE AREA

U3

1

Pin no.

J5 Autoconnect

J11

Connector locations

5-5

4060-xxx

Low voltage power supply
CN pin
no.

Connector
CN1 Fuser lamp AC

9

18

1

10

CN2

CN2 DC output

5-6

Service Manual

Signal

1

AC fuser lamp

2

Not used

3

AC fuser lamp

1

+5 V dc

2

+5 V dc

3

Ground

4

Ground

5

Ground

6

Ground

7

+24 V dc

8

+24 V dc

9

Heat on

10

+5 V dc

11

+5 V dc

12

Ground

13

Ground

14

Ground

15

Ground

16

+24 V dc

17

ZC Out*

18

+42 V dc

F1
CN1

SK1
F2

4060-xxx

Output expander control board
Connector

Pin no.

J1A
Autoconnect

1

+24 V dc

2

Ground

3

+5 V dc

1

Prtxdin

2

Ground

3

prtrxd

4

Ground

5

N/C

1

+24 V dc

2

Ground

3

+5 V dc

1

prtxdout

2

Ground

3

prtrxd

4

Ground

1

Ground

2

Paper Present

3

RVsnsr

1

mtrout1

2

mtrout2

3

Ground

4

Ground

5

tach +

6

+5 V dc

1

Ground

2

Ground

3

binful

4

binful

5

RVsnsr

1

Not used

2

Not used

3

Not used

J1B

1

J2A
Autoconnect

J6
M

S

J2B

J3 Pass thru
sensor

J4 DC motor

J5 Bin full/near
full dual sensor

J6 Jumper
connector

Signal

Connector locations

5-7

4060-xxx

StapleSmart finisher

Staple card assembly

Pin no.

J1A Bottom
autoconnect

1

+24 V dc

2

Ground

3

+5 V in

1

rtxdin

2

Ground

3

prtrxd

4

Ground

5

Ground

1

fdmtr1

2

fdmtr2

3

Ground

4

Ground

5

tachft

6

5Vptt

1

stpmtr-

2

stpmtr-

3

stpmtr+

4

stpmtr+

5

crtprsnt-

6

stplow+

7

‘stpphomo-

8

Ground

9

5Vstpl

10

stprimed-

1

+24 V dc

2

accmtr-

3

Ground

4

Ground

5

tacha+

6

5Vptt

1

Sol1-

2

+24 V dc

1

Ground

2

pfrinstp+

3

5Vsnsr2

1

J13

1

Connector

J14B
1

J1B Bottom
autoconnect

J14A
J12
1

1
J10

J2 Feed motor

J9
1
J8
1
J7

J3 Stepper
motor

1

J15

J6
1
J5
1
1 J1A

J4
1
1 J1B

1

J2

1

J3

J4 Accessory
connector

J5 Solenoid

J6 Stapler

5-8

Service Manual

Signal

4060-xxx

Connector
Staple card assembly (continued)

J7 Right side
sensor board
1

J13

1
J14B
1
J14A

J8 Solenoid
J12
1

1
J10

J9 Bin empty
sensor

J10 Left side
sensor board

J9
1
J8
1

J12 Pass thru
sensor

J7
1

J15

J6
1

J13 Cover open
switch

J5
1

J14A
1 J1A

J4
1
1 J1B

1

J2

1

J3

J14B

J15 Stapler
door open

Pin no.

Signal

1

Ground

2

Bottom

3

Top

4

Ground

1

Sol2-

2

+24 V dc

1

Ground

2

bnempty-

3

5Vsnsr2

1

Ground

2

full+

3

NRFull+

4

Ground

1

Ground

2

psthruint

3

5Vptt

1

+5V dc

2

Ground

3

cvropin-

1

+24V dc

2

Ground

3

5V in

1

prtxdout

2

Ground

3

prtrxd

4

Ground

5

Ground

1

Dooropin-

2

Ground

3

5Vswitch

Connector locations

5-9

4060-xxx

System board—non-network
1
1
1
1
J14
J11
J19
J15
J9

+24V
1+3 3V
GND

1

1

+42V
+5V
HEAT

J5
1

J4

J3

J29
1

1

1

1

FRU No
XXXXXX

J2

J8

J10

J27

J16
1

50
99
49 100

J13

5-10

Service Manual

J20

J34

J31
1

1

1 J28

OPTION CARD

J7

J22

1 1
J24 1 J26 J32

OPTION CARD

1

4060-xxx

System board—network
1
1
1
1
J14
J11
J19
J15
J9
J7

J22

+24V
1+3 3V
GND

1

1

1 1
J24 1 J26 J32

+42V
+5V
HEAT

J5

J4

J3

1

1

1

1

1

FRU No
XXXXXX

J2

J34

J31

1 J28

OPTION CARD

1

J29
1

OPTION CARD

1

J8

J10

J27

J16
1

50
99
49 100

J13

J23

Connector locations 5-11

4060-xxx

System board–non-network and network (see “System board–non-network” on page 5-10 or
“System board–network” on page 5-11)
Connector

Pin no.

J1 (not used)
J2 Printhead (laser cable)

J3 Cover closed switch

J4 Printhead (HSYNC)

J5 Printhead (mirror motor)

J6 Printhead fan (400/410)

J7 Main fan

Signal
N/A

1

Video Level 2+

2

Video3*

3

Ground

4

+5PHead

5

LPOW

6

LADJ*

7

LPOW FB

8

LENA*

1

Cov Closed

2

Ground

3

+5V dc

1

+5V dc

2

HSYNC ID

3

HSYNC IN

4

Ground

1

Ground

2

Ground

3

MM REF R

4

MM LOCK*

5

MM Stgart*

6

Ground

7

+24V dc

1

+24V dc

2

PH FAN*

1

FANSTALL

2

Ground

3

MAINFAN

1

CARTFAN

2

Ground

1

HOP FULL*

2

Ground

3

HOP LED

4

Ground

J8 SDRAM memory
J9 Cartridge fan

J10 SDRAM memory
J11 Output level (output bin sensor)

J12 (not used)

5-12

Service Manual

1

4060-xxx

System board–non-network and network (see “System board–non-network” on page 5-10 or
“System board–network” on page 5-11)
Connector

Pin no.

J13 USB connector

J14 Fuser DC

J15 Operator Panel

Signal

J1 G12

Ground

1

USB +5

2

USB MINUS 2

3

USB PLUS 3

4

Ground

J1 G2

Ground

1

NARMEDIA*

2

Ground

3

THERM

4

Ground

5

THUMP

6

+5V dc

7

THUMPRET

8

EXIT SNS*

1

OPPAN INT

2

Ground

3

I2C CLK R

4

+5V dc

5

I2C DAT R

1

SM Cart

2

Ground

3

Ground

J16 (not used)
J17 (not used)
J18 (not used)
J19 Smart cartridge

J20 Parallel port (not used for network model)

J16
1

50
99
49 100

J20

J21 (not used)

Connector locations 5-13

4060-xxx

System board–non-network and network (see “System board–non-network” on page 5-10 or
“System board–network” on page 5-11)
Connector

Pin no.

J22 HVPS

input sensor

cartridge sensor

Signal

1

ATSERVO

2

TXCURPWM

3

TXENABLE

4

TDXPWM

5

+24V dc

6

CHGPWM

7

Ground

8

DEVB

9

Ground

10

INSENSE

11

+5V dc

12

TONER WHEEL

13

Ground

1

ON/OFF

2

Ground

3

BLDC CLK

4

+5V dc

5

MTR1

6

DIR

7

BLDC HALL

8

BLDC LOCK

9

Ground

10

Ground

11

+24V dc

J23 (not used for non-network model)

J16
1

50
99
49 100

J23

J24 BLDC main drive motor

5-14

Service Manual

4060-xxx

System board–non-network and network (see “System board–non-network” on page 5-10 or
“System board–network” on page 5-11)
Connector

Pin no.

J25 Autocomp motor

J26 MPF paper out

Signal

1

+5V_TRAY1

2

+5v_SWITCHED

3

PAPER_OUT-IN

4

AUTOCOMP_ENC

5

PAPER_LOW_IN

6

Ground

7

Ground

8

Ground

9

AUTOCOMP_OUT1

10

AUTOCOMP_OUT2

1

MPF POUT

2

Ground

3

MPF LED

1

+24V dc

2

AutoComp*

1

RXD1R

2

Ground

3

TXD1BR

4

Ground

1

RXD1R

2

Ground

3

TXD1BR

4

Ground

1

MPFPick*

2

+24V dc

J27 (not used)
J28 Autocompensator
internal tray
J29 Bottom options

J30 (not used)
J31 top options

J32 MPF pick solenoid

J33 Ethernet connector

Connector locations 5-15

4060-xxx

System board–non-network and network (see “System board–non-network” on page 5-10 or
“System board–network” on page 5-11)
Connector

Pin no.

J34 Paper size sensor

autocomp motor

J35 System board edge
connector
J36 (not used)
J37 (not used)
J40 SDRAM (on board)

5-16

Service Manual

Signal

1

PSIZE2

2

Ground

3

PSIZE1

4

PSIZE3

5

Ground

6

TRAY1 POUT

7

TRAY1 PLOW*

8

+3.3V dc

9

ENCODER

10

+5V dc

4060-xxx

6. Preventive maintenance
This chapter describes procedures for printer preventive maintenance. Following these
recommendations can help prevent problems and maintain optimum performance.

Safety inspection guide
The purpose of this inspection guide is to aid you in identifying unsafe conditions.
If any unsafe conditions exist, find out how serious the hazard could be and if you can continue
before you correct the hazard.
Check the following items:

• Damaged, missing, or altered parts, especially in the area of the on/off switch and the power
supply.

• Damaged, missing, or altered covers, especially in the area of the top cover and the power
•

supply cover.
Possible safety exposure from any non-Lexmark attachments.

Lubrication specifications
No requirements for this printer.

Scheduled maintenance
The operator panel displays the message “80 Scheduled Maintenance” at each 300K page count
interval. It is necessary to replace the fuser assembly, transfer roller, charge roll, and pick tires at this
interval to maintain the print quality and reliability of the printer. The parts are available as a
maintenance kit with the following part numbers:
Maintenance kits
Part number
Description
000/010, 200/210

400/410

115 V Maintenance kit

56P1409

56P1855

220 V Maintenance kit

56P1412

56P1856

100 V Maintenance kit

56P1413

56P1857

After replacing the kit, the maintenance count must be reset to zero to clear the “80 Scheduled
Maintenance” message. See “Maintenance page count” on page 3-17.

Preventive maintenance

6-1

4060-xxx

6-2 Service Manual

4060-xxx

7. Parts catalog
How to use this parts catalog
• SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown
•
•

on the same list. Common parts are shown by one index number. Parts peculiar to one or the
other of the assemblies are listed separately and identified by description.
NS: (Not Shown) in the Asm–Index column indicates that the part is procurable but is not
pictured in the illustration.
PP: (Parts Packet) in the Description column indicates the part is contained in a parts packet.

The parts catalog uses the last three digits of the type to identify model specific replacement FRUs.
Model name

Configuration

Machine type

Parts catalog

Lexmark T630

Non-network

4060-000

Lexmark T630n

Network

4060-010

010

Lexmark T632

Non-network

4060-200

200

Lexmark T632n

Network

4060-210

210

Lexmark T634

Non-network

4060-400

400

Lexmark T634n

Network

4060-410

410

000

Parts catalog

7-1

4060-xxx

Assembly 1: Covers
1

2

3

4

4

19

3
18
17
5

16
15

14

6
13

8
12
7
11
9
10

7-2 Service Manual

4060-xxx

Assembly 1: Covers
AsmIndex

Part
number

Units

Description

1–1

56P1300

1

Cover, fuser wick assembly

2

99A2074

1

Cover assembly, redrive cap

3

56P1301

1

Cover assembly, laser assembly, 250-sheet output, 000/010

3

56P1302

1

Cover assembly, laser assembly, 500-sheet output, 200/210/400/410

4

99A1587

1

Support, paper

5

56P1305

1

Hinge, upper front cover

6

56P1306

1

Cover, right side, 250-sheet output, 000/010

6

56P1307

1

Cover, right side 500-sheet output, 200/210/400/410

7

99A0007

1

Label, TLI/ID/serial number–blank

8

56P1303

1

Upper front cover with Lexmark logo

9

56P1308

1

Latch, upper cover

10

56P1309

1

Cover assembly, lower front

11

99A0004

1

Spring, latch

12

56P1356

1

Cover, clear bezel, 000/010

12

56P1358

1

Cover, clear bezel, 200/210

12

56P1862

1

Cover, clear bezel, 400/410

13

56P1753

1

Kit, operator panel overlay–English, Brazilian Portuguese, French, and Spanish

13

56P1754

1

Kit, operator panel overlay–Dutch, French, German, and Italian

13

56P1755

1

Kit, operator panel overlay–Czech and Hungarian

13

56P1756

1

Kit, operator panel overlay–Danish, Finnish, Norwegian, and Swedish

13

56P1757

1

Kit, operator panel overlay–Polish, Russian, and Turkish

13

56P1758

1

Kit, operator panel overlay–WW English and Spanish

13

56P1759

1

Kit, operator panel overlay–WW English, Simplified Chinese, Traditional Chinese, and
Japanese

14

56P1310

1

Operator panel assembly 110V

14

56P1311

1

Operator panel assembly 220V

15

56P1394

1

Cable assembly, operator panel

16

56P2122

1

Cover, left door, 250 1-slot, 000/010

17

99A1524

1

Cartridge load spring

18

56P1395

1

Switch, cover closed w/cable assembly

19

56P2126

1

Cover, left door, 500 2-slot, 200/210/400/410

NS

99A0577

1

Parts packet, cable ties (10 each)

NS

99A1594

1

Retainer, cable

NS

99A0263

5

Parts packet, screw (left side cover mounting)

NS

99A0263

3

Parts packet, screw (right side cover mounting)

NS

99A0263

6

Parts packet, screw (laser cover)

NS

99A0263

5

Parts packet, screw (upper front cover mounting)

Parts catalog

7-3

4060-xxx

Assembly 2: Frame 1

8

2

1

3

3

7

4
6
4
5

7-4 Service Manual

4060-xxx

Assembly 2: Frame 1
Asmindex

Part
number

Units

Description

2–1

56P1322

1

Frame, EP module, 000/010

1

56P1347

1

Frame, EP module, 200/210/400/410

2

56P1320

1

Right side frame assembly

3

99A1540

4

Nut plate, frame extension, 200/210/400/410

4

99A0263

4

Parts packet, screw

5

99A1518

1

Frame extension, right, 200/210/400/410

6

99A1538

1

Contact, RSF ground

7

99A1517

1

Frame extension, left, 200/210/400/410

8

56P1321

1

Left side frame

Parts catalog

7-5

4060-xxx

Assembly 3: Frame 2
38
1

2
31

30

37
36
35
32 33

29

3

28

4
5

27
34

6

7

26
25
24
8

23
5

9
22
10

14

8

21

16

11

8

5

19
15

20

13
18
17

7-6 Service Manual

14

8

12

5

4060-xxx

Assembly 3: Frame 2
Asmindex

Part
number

Units

Description

3–1

99A1857

1

Upper redrive deflector

2

99A0104

1

Upper diverter spring

3

99A2151

1

Redrive assembly, 250 in/250 out, 000/010

3

56P1328

1

Redrive assembly, 500 in/500 out, 200/210/400/410

4

56P1318

1

Duct, main cap

5

99A0263

3

Parts packet, screw

6

99A2021

1

Support, right stacker plate, 000/010

6

56P1319

1

Support, right stacker plate, 200/210/400/410

7

99A2020

1

Transfer plate assembly

8

99A2077

4

Pad, machine mounting

9

56P1399

1

Smart cartridge contact assembly w/cable

10

56P1408

1

Cartridge fan

11

56P1361

1

Toner sensor assembly

12

99A0585

1

Parts packet, contact kit
• Contact, doctor blade/TAR/developer roll (3)
• Contact, PC drum (1)
• Contact, charge roll (1)
• Block, contact mounting (4)
• Screw, contact mounting (5)

13

99A0028

1

Spring, tray bias

14

99A2019

2

Spring, cartridge hold down

15

99A0026

1

Tray bias arm assembly

16

99A0039

2

Roller, developer support

17

99A1525

1

Deflector, upper PF

18

56P1334

1

Deflector, inner, 000/010

18

56P1336

1

Deflector, inner, 200/210/400/410

19

99A0053

1

Sensor, input

20

99A1546

1

Shield, gear #60/MPF

21

99A0549

1

Shield, ESD assembly with label

22

99A2445

1

Guard, gear

23

99A2078

1

Pan, motor drip

24

56P1350

1

Board, input tray (ITC)

25

99A2076

1

Pan, drip ITC

26

99A0063

1

Paper switch activate

27

99A0567

1

Link, gear release

28

99A0556

1

Spring, counterbalance

29

56P1314

1

Shroud, fan, 000/010

29

56P1315

1

Shroud, fan, 200/210/400/410

30

56P1391

1

Sensor, standard bin level with cable

31

99A0062

1

Bracket, level sensor

32

56P1360

1

Fan, main w/cable

33

99A2018

1

Support, left lower stacker

Parts catalog

7-7

4060-xxx

Assembly 3 (cont.): Frame 2
38
1

2
31

30

37
36
35
32 33

29

3

28

4
5

27
34

6

7

26
25
24
8

23
5

9
22
10

14

8

21

16

11

8

5

19
15

20

13
18
17

7-8 Service Manual

14

8

12

5

4060-xxx

Assembly 3 (cont.): Frame 2
Asmindex

Part
number

Units

Description

3–34

99A1596

1

Contact, LSF ground

35

56P1317

1

Duct, left stacker, 250-sheet, 000/010

35

99A2016

1

Duct, left stacker, 500-sheet, 200/210/400/410

36

99A1644

1

Door assembly, redrive 250 sheet

37

99A1613

1

Flag, output paper level, 000/010

37

56P1316

1

Flag, output paper level, 200/210/400/410

38

99A2017

1

Guide, extension

NS

99A1541

1

Clip, external ground

NS

99A0263

17

Parts packet, screw

Parts catalog

7-9

4060-xxx

Assembly 4: Printhead 1 (000/010)
2

3
2
5

1

4

000/010

Asmindex

Part
number

Units

Description

4–1

56P1386

1

Cable, laser

2

99A0263

3

Parts packet, screw (printhead mounting)

3

56P1396

1

Printhead assembly (includes all cables), 000/010

4

56P1387

1

Cable, HSYNC

5

56P1388

1

Cable, mirror motor, 000/010

7-10 Service Manual

4060-xxx

Assembly 5: Printhead 2 (200/210)
1

2

3

2

Top
View
4

Bottom
View

200/210

Asmindex

Part
number

Units

Description

5–1

56P1386

1

Cable, laser

2

99A0263

3

Parts packet, screw (printhead mounting)

3

56P1443

1

Printhead assembly (includes all cables), 200/210

4

56P1387

1

Cable, HSYNC

Parts catalog 7-11

4060-xxx

Assembly 6: Printhead 3 (400/410)
1

3

2

2

Top
View
4

Bottom
View

400/410

Asmindex

Part
number

Units

Description

6–1

56P1386

1

Cable, laser

2

99A0263

3

Parts packet, screw (printhead mounting)

3

56P1854

1

Printhead assembly (includes all cables), 400/410

4

56P1387

1

Cable, HSYNC

7-12 Service Manual

4060-xxx

Assembly 7: Paper feed–autocompensator

7
6

5
4
2
1

3

Asmindex

Part
number

Units

Description

7–1

56P1325

1

Pick arm assembly (500-sheet), 200/210/400/410

1

56P1326

1

Pick arm assembly (250-sheet), 000/010

2

56P1337

1

Parts packet, bellcrank and spring for 250 tray, 000/010

2

56P1331

1

Parts packet, bellcrank and spring for 500 tray, 200/210/400/410

3

99A0070

2

Pick roll assembly

4

56P1324

1

Flag, paper out 250-sheet tray, 000/010

4

56P1323

1

Flag, paper out 500-sheet tray, 200/210/400/410

5

99A0263

1

Parts packet, screw (hanger)

6

56P1406

1

Card asm, paper wt/paper low/out sensor

7

56P1382

1

Int. card/autocomp card cable (paper low/out sensors)

Parts catalog 7-13

4060-xxx

Assembly 8: Paper feed–multipurpose feeder

1
2
3

13

5
12
4
11
6
10

7
9
5

8

7

7-14 Service Manual

4060-xxx

Assembly 8: Paper feed–multipurpose feeder
Asmindex

Part
number

Units

Description

8–1

99A0075

1

Screw, socket set M4X5 mm

2

99A0071

1

Arm assembly, MPF

3

99A0076

1

Pick roll assembly

4

99A0084

1

Flag, MPT paper out

5

56P1352

1

MPF pad/separator arm assembly, includes:
• Pad, restraint
• Pad, separator
• Housing, separator pad
• Spring, sep pad
• Arm, separator
• Spring, sep

6

99A1531

1

MPF lower deflector

7

99A0263

2

Parts packet, screw (lower deflector mounting 8 mm)

7

99A0263

2

Parts packet, screw (lower deflector mounting 12 mm)

8

99A2071

1

Sensor, MPF paper out

9

99A0081

1

Spring assembly, separator

10

99A0263

1

Parts packet, screw (frame mounting)

11

99A0073

2

Screw, damper

12

99A0074

2

Bushing, pick roll shaft

13

56P2407

1

MPF frame assembly with solenoid

NS

99A0267

2

Parts packet, clip (pick roll shaft)

Parts catalog 7-15

4060-xxx

Assembly 9: Paper feed–alignment

1

2
3
4

7-16 Service Manual

4060-xxx

Assembly 9: Paper feed–alignment
Asmindex

Part
number

Units

Description

9–1

56P1327

1

Alignment assembly paper feed

2

99A0263

1

Parts packet, screw (clip ref ground mounting)

3

56P1349

1

Clip, reference ground

4

56P1346

1

Parts packet (reference adjust)
• Screw, paper reference adjust
• Washer, paper reference adjust
• Nut, paper reference adjust

NS

99A0263

3

Parts packet, screw (alignment asm mounting)

Parts catalog 7-17

4060-xxx

Assembly 10: Integrated paper tray–250-sheet

1
2

10
11

4

3

9
8

5

7
6

7-18 Service Manual

4060-xxx

Assembly 10: Integrated paper tray–250-sheet
Asmindex

Part
number

Units

Description

10–1

99A1536

1

2

99A1601

1

Tray, integrated 250-sheet
Latch, back restraint

3

99A2160

1

Restraint, back 250-sheet tray

4

99A0120

2

Restraint pad

5

99A1894

1

Restraint, side 250-sheet tray

6

99A0119

4

Wear strips

7

99A1812

1

Label, tray option number

8

99A0121

1

Clip, 250-sheet tray wear

9

99A0126

3

Finger, autosize

10

99A0124

1

Plate, snap-in

11

99A0127

1

Slider, autosize 250-sheet

Parts catalog 7-19

4060-xxx

Assembly 11: Integrated paper tray–500-sheet

11
10

1

9
7
8

6
5

4
2

3

7-20 Service Manual

4060-xxx

Assembly 11: Integrated paper tray–500-sheet
Asmindex

Part
number

Units

Description

11–1

99A1576

1

Tray assembly 500-sheet

2

99A1895

1

Restraint, side

3

99A0292

4

Strip, wear

4

99A1812

1

Label, tray option number

5

99A1583

1

Plate, 500-sheet tray wear

6

99A0126

3

Finger, autosize

7

99A0124

1

Plate, snap-in

8

99A1582

1

Slider, autosize 500-sheet

9

99A0120

2

Restraint pad

10

99A2093

1

Restraint, back

11

99A1601

1

Latch, back restraint

Parts catalog 7-21

4060-xxx

Assembly 12: Drives–Main drive and developer drive

1

4

7

5
3
2
6

7-22 Service Manual

4060-xxx

Assembly 12: Drives–Main drive and developer drive
Asmindex

Part
number

Units

Description

12–1

56P1330

1

Gearbox, w/motor, 000/010

1

56P1332

1

Gearbox, w/motor, 200/210

1

56P1858

1

Gearbox, w/motor, 400/410

2

99A0134

1

Shaft, power takeoff 250, 000/010

2

99A1569

1

Shaft, power takeoff 500, 200/210/400/410

3

99A0275

1

Spring, power takeoff shaft

4

56P2162

1

Gear, bevel with grease packet and washer

5

99A1544

1

Developer drive assembly

6

99A2081

1

Parts packet, developer drive shaft, coupler gear #55

7

99A0263

3

Parts packet, screw (developer drive ground)

NS

99A0263

4

Parts packet, screw (gearbox mounting)

NS

99A0263

3

Parts packet, screw (motor mounting)

Parts catalog 7-23

4060-xxx

Assembly 13: Hot roll fuser
1

2

3
5
4

5

6

9

7

7-24 Service Manual

8

7

4060-xxx

Assembly 13: Hot roll fuser
Asmindex

Part
number

Units

Description

13–1

56P1333

1

Fuser assembly w/115V lamp, 000/010/200/210

1

56P1338

1

Fuser assembly w/100V lamp, 000/010/200/210

1

56P1335

1

Fuser assembly w/220V lamp, 000/010/200/210

1

56P1859

1

Fuser assembly w/115V lamp, 400/410

1

56P1860

1

Fuser assembly w/220V lamp, 400/410

1

56P1861

1

Fuser assembly w/100V lamp, 400/410

2

99A1658

1

Cover, fuser wiper cavity

3

56P1415

1

Wiper assembly, wet

4

56P1348

1

Kit, fuser cover assembly with thermistor, thermal fuse, and L & R fuser lamp contact
assemblies, w/ fuser cover control card

5

99A0263

4

Parts packet, screws:
• Contact assembly (4)
• Solenoid mounting (1)
• Board cover mounting (1)
• Fuser cover assembly (4)
• Hanger (7)

6

56P1362

1

Lamp, 115V, 000/010/200/210

6

56P1363

7

1

Lamp, 220V, 000/010/200/210

2

Screw, PP 99A0263

8

56P1402

1

Sensor, narrow media

9

56P1403

1

Sensor, exit

Parts catalog 7-25

4060-xxx

Assembly 14: Transfer/charging
1

4
2
3

10
5
6

9
7
8

7-26 Service Manual

4060-xxx

Assembly 14: Transfer/charging
Asmindex

Part
number

Units

Description

14–1

99A0512

1

2

99A1017

1

Parts kit, charge roll link asm, left side
Roll assembly, charge

3

99A1555

1

Bushing, charge roll

4

99A0513

1

Parts kit, charge roll link asm, right side

5

56P1357

1

Transfer roll assembly

6

99A0349

1

Arm, transfer roll assembly right

7

99A0184

1

Spring, transfer roll right

8

99A0185

1

Shaft, transfer pivot

9

99A0181

1

Spring, transfer roll left

10

99A1578

1

Arm, transfer roll left

NS

99A0263

1

Parts packet, screw (charge roll)

NS

99A0267

1

Parts packet, retainer (pivot shaft)

Parts catalog 7-27

4060-xxx

Assembly 15: Electronics–power supplies

1

7
6
4
3

5

7-28 Service Manual

2

4060-xxx

Assembly 15: Electronics–power supplies
Asmindex

Part
number

Units

Description

15–1

56P1369

1

LVPS, 110 V ac, 000/010

1

56P1371

1

LVPS, 110 V ac, 200/210/400/410

1

56P1372

1

LVPS, 220 V ac, 000/010

1

56P1374

1

LVPS, 220 V ac, 200/210/400/410

2

56P1365

1

Fuse, for 110 V ac LVPS 5 a/250V (fuse F1), 000/010

2

56P1367

1

Fuse, for 220 V ac LVPS 3.15 a/250V (fuse F1), 200/210/400/410

3

56P1366

1

Fuse, for 110 V ac LVPS 10 a/250V (fuse F2), 200/210/400/410

3

56P1364

1

Fuse, for 220 V ac LVPS 6.3 a/250V (fuse F2), 000/010

4

43H5248

1

Power cord set,–USA, Canada, Columbia, Costa Rica, Dominican Republic,
El Salvador, Ecuador, Guatemala, Honduras, Mexico, Nicaragua, Panama,
Puerto Rico, Saudi Arabia, Taiwan (LV), Venezuela, Virgin Islands

4

1332514

1

Power cord set, 8 ft.–Bolivia (HV), Peru (HV)

4

1339538

1

Power cord set –Austria, Belgium, BlueMark, Catalan, CIS, Czechoslovakia, Finland,
France, Germany, Greece, Hungary, Italy, Netherlands, Norway, Poland, Portugal,
Russia, Slovak countries, Spain, Sweden, Turkey

4

1339537

1

Power cord set–Ireland, U.K.

4

1339539

1

Power cord set–Israel

4

1339552

1

Power cord set–Japan

4

1339540

1

Power cord set–Switzerland

4

1339541

1

Power cord set–Botswana, Lesotho, Namibia, Pakistan, South Africa

4

1342534

1

Power cord set, 8 ft.–Chile, Uruguay

4

1339543

1

Power cord set–Denmark

4

1339545

1

Power cord set, 8 ft., right angle–Argentina (HV)

4

1342530

1

Power cord set–Paraguay (HV)

4

43H5546

1

Power cord set–PRC (HV)

4

1339549

1

Power cord set–Brazil (HV)

4

1339551

1

Power cord set–Brazil (LV)

5

56P1375

1

Power supply, high voltage

6

99A0263

1

Parts packet, screw(s):
• System board mtg (2)
• System board mtg Front (2)
• System mtg ground (1)
• HVPS mtg (2)
• INA cover mtg (12)
• Interconnect board mtg (2)
• Interconnect board shield ground (1)
• Interconnect shield mtg (5)
• Outer shield mtg (10)
• Parallel connector mtg (2)

7

56P1385

1

Cable, front harness (HVPS/input sensor/toner sensor)

Parts catalog 7-29

4060-xxx

Assembly 16: Electronics–card assemblies
1

2

10

9

8
7

6

3
4
5

4

7-30 Service Manual

4060-xxx

Assembly 16: Electronics–card assemblies
Asmindex

Part
number

Units

Description

16–1

56P2410

1

System board assembly (non-network), 000
includes 56P1444

1

56P2412

1

System board assembly (non-network), 200
includes 56P1444

1

56P2414

1

System board assembly (non-network), 400
includes 45P1444

2

56P2411

1

System board assembly (network), 010
includes 56P1445

2

56P2413

1

System board assembly (network), 210
includes 56P1445

2

56P2415

1

System board assembly (network), 410
includes 45P1445

3

56P1340

1

Interconnect board assembly 1 slot, 000/010

2

Screws, PP 99A0263

1

Interconnect board assembly 2 slot, 200/210/400/410

4
5

56P1339

6

56P1850

1

Card assembly, Bar code

6

56P2468

1

Card assembly, IPDS and SC5/TNe

6

56P2182

1

Card assembly, ImageQuick

6

56P1851

1

Card assembly, PrintCryption

7

56P1445

1

Card assembly, communications, network

8

56P1444

1

Card assembly, communications, non-network

9

99A0426

2

Screws, parallel connector mounting

10

99A0263

1

Screw, USB attaching

Parts catalog 7-31

4060-xxx

Assembly 17: Electronics–shields

7-32 Service Manual

4060-xxx

Assembly 17: Electronics–shields
Asmindex

Part
number

Units

Description

17–1

99A0263

1

Parts packet, screw (INA cover mounting)

2

99A1611

1

Shield, Ethernet (blank)

3

99A0263

6

Parts packet, screw (outer shield mounting)

3

99A0263

1

Parts packet, screw (inner shield mounting)

4

56P1341

1

Cover, INA flat (blank)

5

56P2404

1

Shield, INA flat non-network

6

56P2405

1

Shield, INA flat network

7

56P1342

1

Shield, inner assembly, 2 slot, 200/210/400/410

8

56P1343

1

Shield, inner assembly, 1 slot. 000/010

9

56P1345

1

Shield, outer 1 slot, 000/010

10

56P1344

1

Shield, outer 2 slot, 200/210/400/410

Parts catalog 7-33

4060-xxx

Assembly 18: Cabling diagrams 1

1
2

3

4

7
8
5
4

6
7

7-34 Service Manual

4060-xxx

Assembly 18: Cabling diagrams 1
Asmindex

Part
number

Units

Description

18–1

56P1408

1

Cartridge fan

2

56P1360

1

Fan, main w/cable

3

56P1391

1

Sensor, standard bin level with cable

4

56P1382

1

Int. card/autocomp card cable (paper low/out sensors)

5

56P1326

1

Pick arm assembly (250-sheet) 000/010

5

56P1325

1

Pick arm assembly (500-sheet) 200/210/400/410

6

56P1383

1

Cable, autoconnect bottom

7

56P1400

1

Autoconnect top, 000/010

7

56P1401

1

Autoconnect top, 200/210/400/410

8

56P1384

1

Cable, main drive motor

Parts catalog 7-35

4060-xxx

Assembly 19: Cabling diagrams 2

1

3

6
2

HVP

S
4

5

LVP

7-36 Service Manual

S

4060-xxx

Assembly 19: Cabling diagrams 2
Asmindex

Part
number

Units

Description

19–1

56P1394

1

Cable assembly, operator panel

2

56P1385

1

Cable, front harness (HVPS/input sensor/toner sensor)

3

56P1395

1

Switch, cover closed w/cable

4

56P1398

1

Sensor, MPF cable

5

56P2407

1

MPF solenoid w/cable

6

56P1399

1

Smart contact assembly w/cable

NS

56P1389

1

Cable, deflector

Parts catalog 7-37

4060-xxx

Assembly 20: Cabling diagrams 3
400/410
200/210
1
1

000/010

2

2

1

7
2

5

3

6

4

7-38 Service Manual

4060-xxx

Assembly 20: Cabling diagrams 3
Asmindex

Part
number

Units

Description

20–1

56P1386

1

Cable, laser

2

56P1387

1

Cable, HSYNC

3

56P1390

1

Cable, system board to fuser board

4

56P1403

1

Exit sensor

5

56P1402

1

Narrow media sensor

6

56P1405

1

Cable, AC fuser lamp to LVPS

7

56P1388

1

Cable, mirror motor, 000/010

Parts catalog 7-39

4060-xxx

Assembly 21: 250-sheet paper tray

7-40 Service Manual

4060-xxx

Assembly 21: 250-sheet paper tray
Asmindex

Part
number

Units

Description

21–1

99A0263

3

Parts packet, screw (option board)

2

56P0557

1

Board, option tray

3

99A0627

1

Jumper, pin

4

99A0263

1

Parts packet, screw (switch spring)

5

99A0063

1

Spring, switch activate

6

99A0445

1

Stud assembly, 250-sheet frame

7

99A0448

1

Arm, paper out 250-sheet

8

99A0263

3

Parts packet, screw (auto comp mounting)

9

99A1054

1

Pick arm assembly

10

99A0277

1

Wear plate, pass thru

11

99A0263

2

Parts packet, screw (wear plate mounting)

12

99A0276

1

500 Drive roll assembly

13

99A0451

1

Roll, skewed backup

14

99A0282

1

Cable, 250-sheet autoconnect

15

99A0450

1

Retainer, roller

16

99A0350

1

Sensor, paper low

17

99A0679

2

Bracket, 250-sheet frame retention

18

99A0677

4

Parts packet, washer

19

99A0263

4

Parts packet, screw

20

99A0070

2

Pick roll assembly

21

99A1638

1

Base, 250-sheet option

22

99A0026

1

Tray bias arm assembly

23

99A0419

1

Spring, tray bias

24

99A0058

4

Pad, machine mounting

25

99A0288

1

Sensor, option pass thru

26

99A1666

1

Label, tray options

27

99A0272

1

Shaft, 250-sheet drive

28

99A0275

1

Spring, power takeoff

29

99A0280

1

Bushing, drive shaft low

30

99A0274

1

Gear, feed roll

31

99A0273

1

Gear, bevel

32

99A0279

1

Bearing, drive shaft

33

99A0281

1

Cable, 250-sheet autoconnect

Parts catalog 7-41

4060-xxx

Assembly 21 (cont.): 250-sheet paper tray
34
46

43
42
41
40

38

44

45

39

35

37
36

7-42 Service Manual

4060-xxx

Assembly 21 (cont.): 250-sheet paper tray
Asmindex

Part
number

Units
1

Description

21–34

99A1536

Tray assembly, 250-sheet option

35

99A0892

1

Restraint, side 250-sheet tray

36

99A0119

4

Wear strips

37

99A1829

1

Label, tray option number

38

99A0121

1

Clip, 250-sheet tray wear

39

99A0126

3

Finger, autosize

40

99A0127

1

Slider, autosize 250-sheet

41

99A0124

1

Plate, snap-in

42

99A1952

1

Label, paper size

43

99A1537

1

Knob, paper size

44

99A0120

2

Restraint pad

45

99A0893

1

Restraint, back 250-sheet tray

46

99A1601

1

Latch, back restraint

NS

99A0286

1

Spring, backup roller

NS

99A1928

1

Spring, bellcrank 250-sheet tray option

NS

99A0438

2

Bushing, drive roll

NS

99A0278

1

Bellcrank, roller release

Parts catalog 7-43

4060-xxx

Assembly 22: 500-sheet paper tray
45
44
43
46

41

39

42

40

1

38
34

3

2

2

31

35

30

37
36

32

33

29

28

27
26

25

4

24

5

23
22
21
6
20

18
16

15

17

19
6

6
7
6

9

14
13

10

12
11

7-44 Service Manual

8

4060-xxx

Assembly 22: 500-sheet paper tray
Asmindex

Part
number

Units

Description

22–1

99A0350

1

Sensor, paper low

2

99A0263

3

Parts packet, screw (auto comp mounting)

3

99A0405

1

Pick arm assembly

4

99A0070

2

Pick roll assembly

5

99A1636

1

Base, 500-sheet tray

6

99A0058

4

Pad, base 500-sheet

7

99A0419

1

Spring, tray bias

8

99A0026

1

Tray bias arm assembly

9

99A0288

1

Sensor, option pass thru

10

99A0895

1

Restraint, side 500-sheet tray

11

99A0292

4

Wear strips

12

99A1829

1

Label, tray option number

13

99A1583

1

Plate, 500-sheet tray wear

14

99A0126

3

Finger, autosize

15

99A0124

1

Plate, snap-in

16

99A1952

1

Label, paper size

17

99A1582

1

Slider, autosize 500-sheet

18

99A0120

2

Restraint pad

19

99A1576

1

Tray assembly, 500-sheet

20

99A1537

1

Knob, paper size

21

99A1602

1

Restraint, back 500-sheet tray

22

99A1601

1

Latch, back restraint

23

99A1666

1

Label, options

24

56P0557

1

Board, option tray

25

99A0447

1

Shaft, 500-sheet drive

26

99A0282

1

Cable, 250 autoconnect

27

99A1750

1

Wear plate, pass thru

28

99A0276

1

500 Drive roll assembly

29

99A0263

2

Parts packet, screw (wear plate mounting)

30

99A0450

1

Retainer, roller

31

99A0451

1

Roller, skewed backup

32

99A0438

2

Bushing, drive roll

33

99A0275

1

Spring, power takeoff

34

99A0263

3

Parts packet, screw (board mounting)

35

99A0267

1

Parts packet, retainer (aligner assembly)

36

99A0280

1

Bearing, drive shaft low

37

99A0446

1

Aligner assembly, paper

38

99A0274

1

Gear, feed roll

39

99A0063

1

Spring, switch activate

Parts catalog 7-45

4060-xxx

Assembly 22 (cont.): 500-sheet paper tray
45
44
43
46

41

39

42

40

1

38
34

3

2

2

31

35

30

37
36

32

33

29

28

27
26

25

4

24

5

23
22
21
6
20

18
16

15

17

19
6

6
7
6

9

14
13

10

12
11

7-46 Service Manual

8

4060-xxx

Assembly 22 (cont.): 500-sheet paper tray
Asmindex
22–40

Part
number

Units

Description

99A0286

1

Spring, backup roller

41

99A1664

1

Bellcrank, roller release

42

99A0273

1

Gear, bevel

43

99A0279

1

Bearing, drive shaft

44

99A0281

1

Cable, 250-sheet autoconnect

45

99A1702

1

Stud assembly, 500 frame

46

99A1645

1

Arm, paper out 500

NS

99A0452

4

Washer, frame mounting

NS

99A1665

1

Deflector, base 500

NS

99A1667

2

Bracket, 500-sheet tray retention

NS

99A1929

1

Spring, bellcrank 500-sheet option tray

Parts catalog 7-47

4060-xxx

Assembly 23: Duplex option

1

7-48 Service Manual

4060-xxx

Assembly 23: Duplex option
Asmindex

Part
number

Units

Description

23–1

56P1414

1

250 duplex assembly

1

56P1416

1

500 duplex assembly

Parts catalog 7-49

4060-xxx

Assembly 24: Envelope feeder
14

2

1

13

12

3

11
10

4
5
6
9
8

7

7-50 Service Manual

4060-xxx

Assembly 24: Envelope feeder
Asmindex

Part
number

Units

Description

24–1

99A0389

1

Paper weight assembly

2

99A1694

1

Guide, edge

3

99A1696

1

Cover, top

4

99A0485

1

Sensor, envelope pass thru

5

99A0393

1

Clutch, restraint/gear

6

99A1697

1

Cover, right side

7

99A0390

1

Support, slide out

8

99A0488

7

Roller, support

9

99A0382

1

Motor, stepper DC

10

99A1666

1

Label, options

11

99A0388

1

Switch, envelope out

12

99A1700

1

Board assembly, electronic control

13

99A0271

1

Parts packet, gear kit

14

99A1698

1

Cover, left side

NS

99A0404

1

Parts packet, retainer (4 mm PP)

NS

99A0404

3

Parts packet, retainer (clip 5 mm shaft)

NS

99A0404

2

Parts packet, retainer (6 mm)

NS

99A0404

3

Parts packet, retainer (7 mm shaft)

NS

99A0384

1

Shaft, drive pressure roller

NS

99A0385

1

Cable, auto connect front

NS

99A0494

1

Spring, cam clutch

NS

99A0427

1

Label, envelope orientation icon

NS

99A0469

1

Deflector guide

NS

99A1699

1

Guard, pass thru sensor

NS

99A0413

6

Screw, top/motor/board

NS

99A0484

1

Belt, gear drive

NS

99A0491

1

Bracket, stack limiter

NS

99A0400

1

Spring, restraint roll shaft

NS

99A0489

1

Spring, latch return

NS

99A0487

1

Flag, envelope out sensor

Parts catalog 7-51

4060-xxx

Assembly 25: Output expander

7-52 Service Manual

4060-xxx

Assembly 25: Output expander
AsmIndex

Part
Number

Units

Description

25–1

99A1857

1

Deflector, upper redrive, also order 99A0104

2

99A0104

1

Spring, upper diverter

3

99A0369

1

Shaft assembly, exit, also order PP 99A0572

4

99A0052

1

Shaft assembly, lower exit, also order PP 99A0572

5

11

Screw, PP 99A0263

6

99A0915

1

Board, output expander DC motor

7

99A0571

1

Cover, front control board with ESD brush

8

99A1817

1

Tray, output expander

9

99A1666

1

Label, options

10

99A1689

1

Spring clutch assembly

11

99A1688

1

Diverter arm

12

99A0482

1

Spring, output tray

13

99A1784

2

Bracket, attach

14

99A0914

1

Output expander assembly, mechanical linkage

15

99A0372

1

Cover, left side

16

99A0415

2

Spring, swing arm

17

99A0481

18

1

Latch, output tray

2

Shaft bearing PP 99A0572

19

99A0409

1

Level sensor bracket

20

99A1580

1

Flag, output paper level

21

99A0414

1

Sensor, dual bin full

Parts catalog 7-53

4060-xxx

Assembly 25 (cont.): Output expander

7-54 Service Manual

4060-xxx

Assembly 25 (cont.): Output expander
AsmIndex

Part
Number

Units

Description

25–22

99A1748

1

Door assembly, rear access

23

99A0368

1

Shaft assembly, lower, also order PP 99A0572

24

99A0363

3

Pulley, drive

25

99A0371

1

Cover, right side

26

99A0361

1

Belt, 160 gear

27

99A0362

1

Arm assembly, belt idler

28

99A0364

1

Spring, belt tensioner

29

99A0351

1

Sensor, output expander pass thru

30

99A0913

1

Shaft assembly, middle 40T, also order PP 99A0572

31

99A0912

1

Frame assembly

Parts catalog 7-55

4060-xxx

Assembly 26: High-capacity output expander

7-56 Service Manual

4060-xxx

Assembly 26: High-capacity output expander
AsmIndex

Part
Number

Units

Description

26-1

99A1748

2

2

99A1785

4

Door asm, rear access
Latch, rear door

3

99A1783

1

Frame, right

4

99A1778

2

Pulley, output tray

5

99A1782

2

Shaft, pulley

6

99A1790

2

Guide, output tray

7

99A1779

2

Spring, output tray

8

99A1746

1

Cover, right

9

99A1747

1

Cover, front

10

99A1701

1

Tray asm, output

11

99A1781

1

Frame, left

12

99A1666

1

Label, options

13

99A1745

1

Cover, left

NS

99A1751

1

Switch asm, tray sensing

NS

99A1777

1

Flag, tray sensing switch

NS

99A1780

2

Gear, damping

NS

99A1744

2

Kit, high-capacity output stacker

Parts catalog 7-57

4060-xxx

Assembly 26 (cont.): High-capacity output expander

AsmIndex

Part
Number

Units

Description

26-14

99A0107

2

Deflector, upper, also order 99A0104

15

99A0104

2

Spring, upper diverter

16

99A0369

1

Shaft asm, exit upper stacker asm

17

99A0052

1

Shaft asm, stacker lower exit upper stacker asm

12

Bearings, shaft PP 99A0572

2

Board asm, high-capacity output stacker

31

Screws, PP 99A0263

1

Arm, diverter

18
19

99A1749

20
21

99A1688

22

99A1689

1

Clutch asm, output stacker

23

99A1784

2

Bracket, attach

24

99A0415

2

Spring, swing arm

25

99A0914

2

Drive asm, output stacker DC motor

26

99A0409

1

Bracket, dual sensor mounting upper stacker asm

27

99A1613

1

Flag, bin full dual sensor upper stacker asm

28

99A0414

1

Sensor asm, bin full dual upper stacker asm

NS

99A1690

1

Belt, 95G lower stacker asm

7-58 Service Manual

4060-xxx

Assembly 26 (cont.): High-capacity output expander

AsmIndex

Part
Number

Units

Description

26-29

99A0913

2

Shaft, 40T middle output stacker

30

99A0368

2

Shaft asm lower

31

99A0363

6

Pulley, drive

32

99A0361

1

Belt, 160G upper stacker asm

33

99A0362

1

Arm asm, belt idler

34

99A0364

2

Spring, belt tensioner

35

99A1791

1

Stacker asm, paper path lower

35

99A1792

1

Stacker, asm paper path upper

36

99A0351

2

Sensor, stacker pass thru

NS

99A1751

1

Switch asm

NS

99A0462

1

Packet grease, IBM #23

NS

99A0627

1

Jumper, 2 pin (use with 99A1749)

Parts catalog 7-59

4060-xxx

Assembly 27: 5-bin mailbox

7-60 Service Manual

4060-xxx

Assembly 27: 5-bin mailbox
AsmIndex

Part
Number

Units

Description

27-1

99A1512

1

Cover, redrive cap

2

99A1710

1

Cover, wire

3

99A1711

1

Cover, top bin

4

99A1785

2

Latch, rear access door

5

99A0104

1

Spring, upper diverter

6

99A1714

1

Door, rear access

7

99A1723

4

Shaft asm, drive

8

99A1724

1

Shaft asm, drive w/gear

9

99A1708

1

Cover, right side

10

99A1725

1

Packet, drive shaft bushing

11

99A1742

2

Sensor, 5-bin mailbox pass thru

12

99A1712

5

Tray, paper cap

13

99A1739

1

Bracket asm, bail attach w/brush

14

99A1743

1

Kit, 5-bin mailbox asm

15

99A1666

1

Label, options

1

Bail, order 99A1743, 5-bin mailbox asm kit

16
17

99A1713

5

Support, paper tray

18

99A1687

5

Stop asm, paper tray

19

99A1735

5

Flag, bin full

20

99A1737

5

Sensor, dual paper height

21

99A1736

5

Cable, dual sensor

22

99A1718

1

Cable asm, lower auto connect

23

99A1716

1

Drive asm, main DC drive

24

99A1740

1

Board asm, 5-bin mailbox system

25

99A1726

1

Frame asm, left w/clutch asm

26

99A1786

1

Gear, drive

27

99A1719

1

Cable asm, upper auto connect

12

Screw, board mounting PP 99A0263

1

Cover, left side

28
29

99A1709

Parts catalog 7-61

4060-xxx

Assembly 27 (cont.): 5-bin mailbox

7-62 Service Manual

4060-xxx

Assembly 27 (cont.): 5-bin mailbox
AsmIndex

Part
Number

Units

Description

27-30

99A1741

4

Spring, diverter

31

99A1727

1

Frame asm, right side

32

99A1728

4

Cam, diverter actuator

33

99A1731

4

Spring, diverter actuator

34

99A1729

4

Latch, diverter actuator

35

99A1730

4

Arbor, diverter actuator

36

99A1789

4

C-clip

37

99A1720

1

Bracket, attach

38

99A1732

4

Solenoid, diverter

39

99A1738

5

Deflector, paper exit w/brush

40

99A1722

4

Deflector, paper

41

99A1787

4

Deflector
Deflector, paper top bin

42

99A1721

1

NS

99A1734

1

Spring, static ground

NS

99A0462

1

Grease packet, IBM #23

NS

99A1715

1

Roller asm, rear access door

NS

99A1717

1

Gear, drive

NS

99A1788

1

Retainer, R-ring

Parts catalog 7-63

4060-xxx

Assembly 28: High-capacity feeder 1

7-64 Service Manual

4060-xxx

Assembly 28: High-capacity feeder 1
Asmindex

Part
number

Units

Description

28–1

99A0660

1

Frame, printer support frame 2

2

99A0675

3

Parts packet, screw
(printer support 2 frame mounting)

3

99A0698

2

Clamp, feed frame

4

99A0675

4

Parts packet, screw (feed frame clamp)

5

99A0691

2

Bearing, Nyliner leadscrew top

6

99A0656

1

Cover, left side

7

99A0681

4

Strip, wear

8

99A1818

1

Strip, wear dimple

9

99A0675

3

Parts packet, screw
(deflector mt 8-18 x 7/8 inch)

10

99A1829

1

Label, tray option number

11

99A0662

2

Transfer leadscrew assembly

12

99A0716

2

Bearing, leadscrew bottom

13

99A0676

4

Parts packet, nut (6-32 hinge mounting)

14

99A0677

4

Parts packet, washer (hinge mounting flat)

15

99A0677

4

Parts packet, washer (hinge mounting star)

16

99A0657

2

Hinge, door

17

99A0655

1

Door assembly, front

18

99A0658

2

Magnet, door

19

99A0650

1

Frame assembly

20

99A0661

1

Tray assembly, elevator

21

99A1806

1

Card assembly, 2000 option control

22

99A0677

4

Parts packet, washer (card asm. mounting)

23

99A0675

4

Parts packet, screw (card asm. mounting)

24

99A0392

1

Kit, door switch spring and bumper

25

99A0677

1

Parts packet, washer (door switch spring mounting)

26

99A0676

1

Parts packet, nut (door switch spring mounting)

NS

99A0690

1

Cable, optical sensor

Parts catalog 7-65

4060-xxx

Assembly 29: High-capacity feeder 2

1
2
2
2

4
2
3

20

2

19

2

2

2

2

4

2

18

5

2
17
6

6

14

16
15

2

4

2

4

12

6

13

6

11
2

4
9

4

6

10
8
6
7

7-66 Service Manual

4

2

4060-xxx

Assembly 29: High-capacity feeder 2
Asmindex

Part
number

Units
3

Description

29–1

99A0188

2

99A0675

Guide, rear paper, use with 99A0219

3

99A0219

4

99A0677

5

99A0719

6

99A0676

7

99A0663

8

99A0664

1

Belt, drive

9

99A1807

1

Cable, AC internal wiring

10

99A0653

1

Switch, lower limit microswitch

11

99A1808

1

Cord, AC external jumper

Parts packet, screws (including):
• Top frame mounting (6)
• Base mounting (2)
• Power supply board mtg (2)
• Sensor bracket mtg (2)
• Support 1 frame mtg (2)
• Screw (2)
1

Frame assembly, top with labels
Parts packet, washers, (including):
• Top frame clamp (2)
• Base mounting (2)
• Motor plate mtg (4)
• Power supply board (2)
• Sensor bracket mtg (2)

1

Clamp, top frame mounting
Parts packet, nuts, (including):
• Base mounting (2)
• 2-56 switch mounting (2)
• Power supply cover (2)
• Power supply ground (2)

1

Pulley, idler

12

99A0714

1

Cover, power supply

13

99A0667

1

Power supply board

14

99A0715

1

Cable, low voltage power supply

15

99A0698

2

Clamp, feed frame

16

99A0685

1

Bushing

17

99A0654

1

Switch, paper low

18

99A0651

1

Sensor assembly, paper out/upper limit

19

99A0659

1

Frame, printer support 1

20

99A0695

1

Parts kit, paper size switch assembly

Parts catalog 7-67

4060-xxx

Assembly 30: High-capacity feeder 3

15

14

13

12

11
6
10

9

5
1

8
3
3
7

2

4
1

7-68 Service Manual

4060-xxx

Assembly 30: High-capacity feeder 3
Asmindex

Part
number

Units

Description

30–1

99A0687

4

Parts packet, mounting feet

2

99A0672

4

Parts packet, foot (stabilizer)

3

99A1793

3

Parts packet, screw w/washer (motor mt)

4

99A1795

1

Motor assembly, DC

5

99A1798

1

Plate, drive pulley

6

99A1794

3

Parts packet, nut and washer (drive pulley plate)

7

99A1796

1

Belt, DC motor drive

8

99A1797

1

Idler pulley, belt tension

9

99A1800

1

Pulley, drive

10

99A1799

1

AC receptacle, lower AC

11

99A1801

1

Retainer, C-clip

12

99A1802

1

AC receptacle, upper AC

13

99A1803

1

Cover, top LVPS

14

99A1804

3

Nut w/lock washer, top LVPS cover mounting

15

99A1805

1

Grommet, top LVPS cover

Parts catalog 7-69

4060-xxx

Assembly 31: High-capacity feeder 4
4

1
2
3

5

6
7

4

8
18

9

17
10
19
11
14
16

12
15
13

7-70 Service Manual

4060-xxx

Assembly 31: High-capacity feeder 4
Asmindex

Part
number

Units

Description

31–1

99A0281

1

Cable, 250-sheet autoconnect

2

99A0279

1

Bearing, drive shaft

3

99A0273

1

Gear, bevel

4

99A0276

1

500 Drive roll assembly

5

99A0263

2

Parts packet, screw (frame mounting)

6

99A0451

1

Roll, skewed backup

7

99A0267

1

Parts packet, retainer (roller)

8

99A0675

2

Parts packet, screw (wear plate mounting)

9

99A0277

1

Wear plate wear, pass thru

10

99A0445

1

Stud assembly, 250-sheet frame

11

99A0280

1

Bearing, drive shaft low

12

99A0275

1

Spring, power takeoff

13

99A0272

1

Shaft, 250-sheet drive

14

99A0446

1

Aligner assembly, paper

15

99A0267

1

Parts packet, retainer (aligner assembly)

16

99A0274

1

Gear, feed roll

17

99A0278

1

Bellcrank, roller release

18

56P0556

1

Card assembly, 2000 tray option

19

99A0263

3

Parts packet, screw (tray option card mounting)

NS

99A0675

10

Parts packet, screw (door to door frame mounting)

NS

99A0676

6

Parts packet, nut support frame 1 hex, support frame 2, hex

NS

99A0677

6

Parts packet, washer (support frame 1 star, support frame 2 star)

NS

99A0684

1

Cable, HCIT-14 pin flex

NS

99A0286

1

Spring, backup roller

Parts catalog 7-71

4060-xxx

Assembly 32: High-capacity feeder 5
1

2

10

3
11

12

10
4

10

12
10

5
6
7

9

7-72 Service Manual

8

4060-xxx

Assembly 32: High-capacity feeder 5
Asmindex

Part
number

Units

Description

32–1

99A0263

3

Parts packet, screw
(auto comp assembly mounting)

2

99A1055

1

Arm assembly, pick 2000

3

99A0070

2

Roll assembly, pick

4

99A0692

1

Base, 2000 option

5

99A0263

1

Parts packet, screw (deflector mounting)

6

99A0678

1

Deflector, base

7

99A0288

1

Sensor, pass thru

8

99A1812

1

Label, tray option number

9

99A1666

1

Label, options

10

99A0677

4

Parts packet, washer
(bracket 250-sheet frame retention mounting)

11

99A0263

4

Parts packet, screw
(bracket 250-sheet frame retention mounting)

12

99A0679

2

Bracket, 250-sheet frame retention

NS

99A0717

1

Cable, paper low switch

NS

99A0720

1

Cable, lower limit switch

Parts catalog 7-73

4060-xxx

Assembly 33: Kiosk–vertical paper adapter
2

1

3

4

7

5

21

4

4

7
6

5

8

4

5
4
10
11
9

12
5
20
11
12

19

11
13

5

14

5

6
15
18

6
10

4
16
4
17

7-74 Service Manual

4
10

4060-xxx

Assembly 33: Kiosk–vertical paper adapter
Asmindex

Part
number

Units

Description
Bail, support

33–1

99A0231

1

2

99A1646

1

Arm assembly, pivot

3

99A1819

1

Mounting, frame assembly

4

99A0240

12

Parts packet, retainer

5

99A0234

16

Parts packet, screw

6

99A1705

1

Gear, idler

7

99A1704

2

Gear, idler

8

99A0197

1

Shaft, drive rear

9

99A0079

1

Tray assembly, backup roller

10

99A0208

3

Parts packet, pulley

11

99A0087

6

Spring, backup roller

12

99A0086

6

Roller, backup

13

99A1706

1

Tray assembly, drive roller

14

99A0125

1

Frame assembly, right side

15

99A0232

1

Cover, right

16

99A1820

2

Belt, 185G

17

99A0226

1

Guide, paper exit

18

99A0122

2

Shaft assembly, drive roller

19

99A0137

1

Frame assembly, left side

20

99A0088

1

Cover, backup tray

21

99A0085

1

Tray, backup roller

Parts catalog 7-75

4060-xxx

Assembly 34: Kiosk–horizontal paper adapter
2

1

3

4

7

5

20

4

7

4
6

5

8

4

5

4
10
11
9

12
5
19

11
12

18

11
13

5

14

5

5
15
17
10

4
16
4

4
10

7-76 Service Manual

4060-xxx

Assembly 34: Kiosk–horizontal paper adapter
Asmindex

Part
number

Units

Description
Bail, support

34–1

99A0231

1

2

99A1646

1

Arm assembly, pivot

3

99A1819

1

Mounting, frame assembly

4

99A2409

12

Parts packet, retainer

5

99A0234

15

Parts packet, screw

6

99A1705

1

Gear, idler

7

99A1704

2

Gear, idler

8

99A0197

1

Shaft, drive rear

9

99A0079

1

Tray assembly, backup roller

10

99A0208

3

Parts packet, pulley

11

99A0087

6

Spring, backup roller

12

99A0086

6

Roller, backup

13

99A1707

1

Tray assembly, drive roller

14

99A0907

1

Frame assembly, right side

15

99A0232

1

Cover, right

16

99A1820

2

Belt, 185G

17

99A0122

2

Shaft assembly, drive roller

18

99A0906

1

Frame assembly, left side

19

99A0088

1

Cover, backup tray

20

99A0085

1

Tray, backup roller

Parts catalog 7-77

4060-xxx

Assembly 35: StapleSmart finisher I

1
18

2

3

17
16

4
5

5

15
6
9

10
11
14
13

7-78 Service Manual

12

8

7

4060-xxx

Assembly 35: StapleSmart finisher 1
Asmindex

Part
number

Units

Description

35–1

99A2505

1

Cover, top assembly

2

99A2510

1

Clip, brush ground

3

99A2506

1

Top cover bail/plate, right side

4

99A2512

1

Door, rear access

5

99A1785

2

Latch, rear access door

6

99A2501

1

Cover, right base assembly

7

99A2503

1

Cover, stapler access

8

99A2502

1

Switch, stapler access door assembly

2

Screws, switch (stapled access) mounting 99A2509 Parts Packet

9
10

99A2519

1

Cover, accumulator assembly

11

99A2520

1

Tray, output assembly

11

99A2542

1

Tray, output

12

99A1666

1

Label, tray options

13

99A2521

1

Sensor, stapler bin empty

14

99A2541

1

Sensor cover, stapler bin empty

15

99A2511

1

Bail, center stapler

16

99A2508

1

Kit, stacking bail

17

99A2500

1

Cover, left base assembly

18

99A2507

1

Top cover bail/plate, left side

Parts catalog 7-79

4060-xxx

Assembly 36: StapleSmart finisher 2
14

1
13

12

2
3
5

7

6

4

4

10
4

7-80 Service Manual

4

9

11

8

4

4060-xxx

Assembly 36: StapleSmart finisher 2
Asmindex

Part
number

Units

Description

36–1

99A2575

1

Stapler cartridge holder 321-C

2

99A2526

1

Stapler assembly

3

99A2556

1

Bracket, attach

4

99A0263

1

Parts packet, screws

5

99A1820

1

Belt, 185G

6

99A2544

1

Card assembly, right stapler bin level

7

99A0362

1

Arm assembly, belt idler

8

99A2545

1

Spring, swing arm

9

99A2548

1

Bumper, output tray

10

99A2533

1

Bar, upper output tray

11

99A2523

2

Spring, output tray

12

99A2543

2

Cover, optical sensor

13

99A2528

1

Frame assembly, right

14

99A2557

1

Clip, static ground

Parts catalog 7-81

4060-xxx

Assembly 37: StapleSmart finisher 3
2

1
24

1

3

25

5
26

1

27
8

4
6
7
15

1
22
21

23

6

14
4

10
13
12

1

10

1
16
20

10

9
10

19
11

18

10
17

7-82 Service Manual

4060-xxx

Assembly 37: StapleSmart finisher 3
Asmindex

Part
number

Units

Description

37–1

99A0263

1

Parts packet, screws

2

56P1747

1

System card assembly, stapler option

3

99A2531

1

Switch assembly, top cover open

4

99A2539

1

Flange, pulley

5

99A0104

1

Spring, upper diverter

6

99A2540

4

Bearing, redrive

7

99A2517

1

Shaft assembly, upper exit

8

99A2516

1

Deflector, upper

9

99A0363

1

Pulley, drive

1

Bearings, 500-sheet stacker PP 99A0572

10
11

99A0368

1

Shaft assembly, lower

12

99A0913

1

Shaft assembly, 40T middle stacker

13

99A2515

1

Shaft assembly, upper drive

14

99A2518

1

Shaft assembly, lower exit

15

99A2538

1

Belt, FHT 86T

16

99A2543

1

Cover, optical sensor

17

99A2529

1

Guide, inner bias

18

99A2527

1

Frame assembly, left

19

99A2533

1

Bar, upper output tray

20

99A2523

1

Spring, output tray

21

99A2548

1

Bumper, output tray

22

99A2549

1

Card assembly, left stapler bin level

23

99A1717

1

Gear, drive

24

99A2513

1

Motor assembly, drive

25

99A2551

1

Clutch assembly, stapler option

26

99A2547

1

Pulley, belt idler

27

99A2552

1

Bushing, tensioner CBM

Parts catalog 7-83

4060-xxx

Assembly 38: StapleSmart finisher 4
1

7-84 Service Manual

4060-xxx

Assembly 38: StapleSmart finisher 4
Asmindex

Part
number

Units

Description

38–1

99A2559

1

NS

99A2480

1

Paper alignment wheel
Kit, maintenance StapleSmart wheels

NS

99A2525

1

Sensor, stapler pass thru

NS

99A2530

1

Cable assembly, right stapler bin level

NS

99A2534

2

Ground cable, stapler tray bar

NS

99A2524

1

Cable, stapler

NS

99A2532

1

Cable, ground

NS

99A2504

1

Cable assembly, left stapler bin level

NS

99A2546

1

Label, pinch point

NS

99A0548

1

Tie, cable

Parts catalog 7-85

4060-xxx

Assembly 39: Options
Asmindex

Part
number

Units

Description

NS

56P0695

1

8MB memory option

NS

56P0696

1

16MB memory option

NS

56P0697

1

32MB memory option

NS

56P0698

1

64MB memory option

NS

56P0699

1

128MB memory option

NS

56P1417

1

16MB Flash card

NS

56P1418

1

32MB Flash card

NS

56P1850

1

Card assembly, Bar Code

NS

56P2468

1

Card assembly IPDS and SCS/TNe

NS

56P1851

1

PrintCryption card assembly

NS

56P1419

1

Hard disk, with adapter 20+GB

NS

99A0629

1

Adapter card, SES for SCS

NS

13A0296

1

Cable, Twinax

NS

13A0297

1

Cable, Coax

NS

99A0545

1

External serial adapter

NS

13A0298

1

Cable, serial

NS

56P2182

1

Card assembly, ImageQuick

NS

56P1424

1

Optra Forms hard disk, with adapter (20+GB)

NS

99A1890

1

Tray assembly, 250-sheet special media

NS

99A1647

1

Rib assembly, 250-sheet special media tray

NS

99A1654

1

Tray, universal adjustable 250-sheet

NS

56P1100

1

Cartridge, empty shipping

NS

99A1605

1

Kit, cap/stack bails 500-sheet

NS

56P1742

1

MarkNet N2101e Ethernet 10BaseT/100Base TX internal print server

NS

56P1743

1

MarkNet N2104fl-SC fiber optic (10MB) internal

NS

56P1744

1

MarkNet N2103fx-SC fiber optic (100MB) internal

NS

56P1741

1

MarkNet N2100t token ring internal print server

NS

56P0161

1

INA, serial and parallel “C”

NS

56P0162

1

Adapter, parallel 1284 C-B

NS

56P1437

1

Parallel 1284-B interface card

NS

56P1436

1

RS232C serial interface card

NS

99A2485

1

Tray assembly, UAT 400-sheet

NS

56P1435

1

Serial adapter, int w/out +5 V ac

7-86 Service Manual

4060-xxx

Assembly 39 (cont.): Options
Asmindex

Part
number

Units

Description

NS

56P1427

1

Optra Forms 32MB Flash card

NS

56P1428

1

Optra Forms 16MB Flash card

NS

56P1429

1

Simplified Chinese font card

NS

56P1430

1

Traditional Chinese font card

NS

56P1438

1

Japanese font card

NS

56P1101

1

Cable assembly, 6’ parallel, A-C

NS

56P0161

1

Cable assembly, SER+PAR 1284C INA

NS

56P0162

1

Cable, parallel 1284 C-B adapter

Parts catalog 7-87

4060-xxx

Assembly 40: Miscellaneous
Asmindex

Part
number

Units
1

Description

NS

99A1633

Parts packet, screw

NS

99A0585

1

Parts packet, contact kit

NS

99A0267

1

Parts packet, retainers

NS

99A0268

1

Parts packet, springs paper feed

NS

99A0269

1

Parts packet, duplex option fan mounting

NS

99A0299

1

Parts packet, duplex option cam follower assembly

NS

99A0271

1

Parts packet, envelope option gears

NS

99A0404

1

Parts packet, retainers envelope option

NS

99A0413

1

Parts packet, screw duplex

NS

99A0572

1

Parts packet, bearings, 500-sheet stacker

NS

99A0577

1

Parts packet, cable ties (10 each)

NS

99A0675

1

Parts packet, screw high-capacity feeder

NS

99A0676

1

Parts packet, nuts high-capacity feeder

NS

99A0677

1

Parts packet, washers high-capacity feeder

NS

99A0083

1

Parts kit, multipurpose tray

NS

99A0512

1

Parts kit, charge roll link asm, left side

NS

99A0513

1

Parts kit, charge roll link asm, right side

NS

99A0702

2

Printer stand caster, non-locking

NS

99A0703

2

Printer stand caster, locking

NS

99A0704

1

Printer stand grommet, wire

NS

99A0705

2

Printer stand lock, cam

NS

99A0706

1

Printer stand storage shelf

NS

99A0707

1

Printer stand door assembly, cabinet

NS

99A0710

1

Printer stand filler, rear top piece

NS

99A0711

1

Printer stand table assembly, large

NS

99A0712

1

Printer stand table assembly, small

NS

99A0208

1

Parts packet, pulley

NS

99A0234

1

Parts packet, screw–kiosk

NS

99A0394

1

Grease packet, Nyogel 744

NS

7371454

1

Relocation kit, 250/250-sheet printer

NS

7371455

1

Relocation kit, 500/250-sheet printer

7-88 Service Manual

4060-xxx

Index
Numerics
1565 Emul Error Load Emul Option 2-32
200 Paper Jam - Remove Cartridge 2-30
201 Paper Jam - Remove Cartridge 2-30
202 Paper Jam - Open Rear Door 2-30
231 Duplex Paper Jam - Rear 2-30
232 Duplex Paper Jam - Rear 2-30
233 Duplex Paper Jam - Rear 2-30
234 Duplex Paper Jam - Rear 2-30
235 Duplex Paper Jam - Front 2-31
236 Duplex Paper Jam - Front 2-31
237 Duplex Paper Jam - Front 2-31
238 Duplex Paper Jam 2-31
239 Duplex Paper Jam 2-31
24x Paper Jam - Check Tray x 2-31
250 Paper Jam - Check MP Feeder 2-31
250-sheet paper tray, option
parts catalog 7-40
removals 4-51
service check 2-64
260 Paper Jam - Check Envelope Feeder 2-31
27x Paper Jam - Check Output 2-31
280 Paper Jam Check Finisher 2-32
281 Paper Jam - Check Finisher 2-32
282 Staple Jam - Check Stapler 2-32
283 Staple Jam - Check Stapler 2-32
500-sheet paper tray, option
parts catalog 7-44
removals 4-51
service check 2-64
5-bin mailbox
parts catalog 7-60, 7-62
service check 2-38
80 scheduled maintenance 6-1
900 error code service check 2-41
950 error code service check 2-42

A
acronyms 1-15
adjustments 4-2
duplex motor drive belts 4-2
fuser solenoid 4-2
gap adjustment 4-3
paper alignment assembly 4-4
printhead assembly 4-3
alignment assembly
adjustment 4-4
parts catalog 7-16
removal 4-52

autocompensator, integrated tray
parts catalog 7-13
pick roll installation 4-39
removal 4-35
autoconnect connections, top 5-1

B
base sensor test 3-16
bevel gear
installation 4-17
removal 4-16
bezel, operator panel removal 4-49
button test 3-8

C
cable diagrams 7-34, 7-36, 7-38
cables
cover closed cable 4-19
operator panel cable removal 4-50
communications board
connections 5-13, 5-14
installation 4-60
parts catalog 7-30
removal 4-18
configuration ID, setting 3-18
connector locations
autoconnect - top 5-1
envelope feeder board 5-2
high voltage power supply (HVPS) 5-4
high-capacity output stacker board 5-3
interconnect board 5-5
low voltage power supply (LVPS) 5-6
output expander 5-7
StapleSmart finisher 5-8
system board (network) 5-11
system board (non-network) 5-10
cover closed switch 2-44, 4-19
covers
parts catalog 7-2
removals 4-9

D
deflector
lower 4-47
upper paper 4-63
developer drive assembly
parts 7-22
removal 4-20

Index

I-1

4060-xxx

diagnostic aids
device tests 3-2
disk test/clean 3-2
flash test 3-3
quick disk test 3-2
diagnostic mode 3-1
duplex tests 3-4
duplex feed 1 test 3-5
duplex feed 2 test 3-6
duplex motor test 3-5
duplex quick test 3-4
duplex sensor test 3-4
error log 3-6
clearing the error log 3-8
printing the error log 3-7
viewing the error log 3-6
finisher tests 3-14
hardware tests 3-8
button test 3-8
LCD test 3-8
parallel wrap test 3-9
ROM memory test 3-9
SDRAM memory test 3-9
input tray tests 3-10
input tray feed test 3-10
paper feed tests
base sensor test 3-16
feed to all bins test 3-12
input tray sensor test 3-10
output bin feed test 3-11
output bin sensor test 3-12
output bin test - standard bin 3-11
print registration 3-16
print tests 3-19
printer setup 3-17
maintenance page count 3-17
restore EP factory defaults 3-18
setting configuration ID 3-18
setting the page count 3-17
viewing the permanent page count 3-17
diagnostic mode 3-1
disabling download emulations 3-3
disk test/clean 3-2
duplex option
parts catalog 7-48
service check 2-47
sub error codes 2-12
duplex tests 3-4

I-2 Service Manual

E
envelope feeder
connections 5-2
parts catalog 7-50
service check 2-49
sub error codes 2-13
EP frame removal 4-20
error codes 2-2
error log 3-6
ESD-sensitive parts 4-1

F
fan removal, main 4-46
feed tests, finisher 3-14
feed to all bins test 3-12
flag
paper bin full sensor 4-54
paper tray paper out sensor 4-51
flash test 3-3
frames
parts catalog 7-4
removals 4-20
fuser
connectors 5-2
installation 4-24
parts catalog 7-24
removals 4-23
service check 2-52
sub error codes 2-11
fuser board 5-2
fuser cover 4-25
fuser exit sensor removal 4-28
fuser lamp removal 4-28
fuser narrow media sensor removal 4-28
fuser solenoid
adjustment 4-2
service check 2-55
fuser transfer plate removal 4-30

H
hardware tests 3-8
high voltage power supply (HVPS)
connectors 5-4
parts catalog 7-28
removal 4-31
high-capacity feeder
locations 5-3
parts catalog 7-64
service check 2-56
high-capacity output stacker
parts catalog 7-56, 7-58, 7-59
service check 2-62
horizontal paper adapter 7-76

4060-xxx

I
inner paper deflector removal 4-33
inner shield
parts catalog 7-32
removal 4-34
input sensor removal 4-34
input tray feed test 3-10
input tray sensor test 3-10
installation
bevel gear 4-17
fuser assembly 4-24
pick roll assembly (integrated tray
autocompensator) 4-39
system board 4-60
integrated tray autocompensator assembly
parts catalog 7-13
removal 4-35
interconnect board
connectors 5-5
parts catalog 7-30
removal 4-40
internal tray card (ITC)
parts catalog 7-6
removal 4-41
service check 2-66
IPDS emulation
user message 2-32

K
kiosk, horizontal paper adapter 7-76
kiosk, vertical paper adapter 7-74

L
lamp, fuser 4-28
laser cover removal 4-14
LCD test 3-8
left door removal 4-9
left side frame removal 4-20
lens cover
see bezel, operator panel
low voltage power supply (LVPS)
connectors 5-6
parts catalog 7-28
removal 4-42
lower deflector assembly removal 4-47
lubrication specifications 6-1

maintenance
ESD-sensitive parts 4-1
lubrication 6-1
maintenance kit 6-1
preventive 6-1
safety inspection guide 6-1
maintenance approach 1-1
maintenance kits 6-1
maintenance page count 3-17
messages
check device connection messages 2-33
service error codes 2-2
user attendance messages 2-19
user line 2 link messages 2-32
user status displays 2-14
user status messages 2-17
warning messages (user status displays) 2-16
models 1-1, 7-1
multipurpose feeder
parts catalog 7-14
pick roll removal 4-55
removal 4-47

N
network system board connectors 5-11

O
operator panel assembly
parts catalog 7-2
removal 4-48
service check 2-70
operator panel bezel, removal 4-49
operator panel cable 4-50
options
parts catalog 7-86
product features 1-2
service checks 2-71
outer shield
parts catalog 7-32
outer shield removal 4-52
output bin feed test 3-11
output bin sensor test 3-12
output bin test - standard bin 3-11
output expander
parts catalog 7-52, 7-54
service check 2-72
output expander control board 5-7

M
main drive assembly
parts catalog 7-22
removal 4-44
service check 2-68
main fan removal 4-46

Index

I-3

4060-xxx

P
packaging 7-88
page count, setting 3-17
paper and media specifications 1-8
paper bin full sensor flag assembly 4-54
paper deflector assembly
inner 4-33
upper 4-63
paper jam
base printer 3-23
diagram 3-22
duplex option 3-24
envelope feeder 3-25
multipurpose feeder 3-25
stapler 3-26
StapleSmart finisher 3-25
trays or bins 3-25
user attendance messages 2-30
paper size sensing board 4-41
parallel wrap test 3-9
part number index 2-7
parts catalog
250-sheet paper tray, option 7-40
500-sheet paper tray, option 7-44
500-sheet tray, integrated 7-20
5-bin mailbox 7-60, 7-62
cabling 7-34, 7-36, 7-38
covers 7-2
drives - main drive/developer drive 7-22
duplex option 7-48
electronics
card assemblies 7-30
power supplies 7-28
shields 7-32
envelope feeder 7-50
frame 7-4, 7-6
high-capacity feeder 7-64
high-capacity output stacker 7-56, 7-58, 7-59
hot roll fuser 7-24
integrated paper tray - 250-sheet 7-18
integrated paper tray - 500-sheet 7-20
kiosk - horizontal paper adapter 7-76
kiosk - vertical paper adapter 7-74
miscellaneous 7-88
optional 250-sheet paper tray 7-40
optional 500-sheet paper tray 7-44
options 7-86
output expander 7-52, 7-54
paper feed
alignment 7-16
autocompensator 7-13
multipurpose feeder 7-14

I-4 Service Manual

printhead
000/010 7-10
200/210 7-11
400/410 7-12
StapleSmart finisher 7-79
transfer⁄ charging 7-26
pick roll (MPT) removal 4-55
pick rolls, integrated tray autocompensator 4-38
power-on self test (POST) 2-34
preventive maintenance 6-1
printhead
adjustment 4-3
parts catalog 7-10, 7-11, 7-12
removal 4-56
service check 2-78

Q
quick disk test 3-2

R
redrive assembly
parts catalog 7-6
removal 4-57
relocation kit 7-88
removals
bevel gear 4-16
communications board 4-18
cover closed switch/cable 4-19
covers 4-9
laser cover 4-14
left door 4-9
right cover removal 4-10
upper front cover 4-12
developer drive assembly 4-20
frames
EP frame 4-20
left side frame 4-20
right side frame 4-22
fuser 4-23
fuser cover removal 4-25
fuser exit sensor 4-28
fuser lamp 4-28
fuser narrow media sensor 4-28
fuser transfer plate 4-30
high voltage power supply 4-31
inner paper deflector assembly 4-33
inner shield 4-34
input sensor 4-34
integrated tray autocompensator assembly 4-35
integrated tray autocompensator pick roll
assembly 4-38
interconnect board assembly 4-40
internal tray card (ITC) 4-41
low voltage power supply (LVPS) 4-42

4060-xxx

lower deflector assembly 4-47
main drive assembly 4-44
main fan 4-46
multipurpose tray/lower deflector assembly 4-47
operator panel assembly 4-48
operator panel bezel 4-49
operator panel cable 4-50
optional paper tray assembly
paper size spring comb 4-51
paper tray autocompensator assembly 4-51
paper tray board 4-51
paper tray frame assembly 4-51
paper tray paper out sensor flag 4-51
outer shield 4-52
paper alignment assembly 4-52
paper bin full sensor flag assembly 4-54
paper size sensing board 4-41
pick roll (MPT) 4-55
printhead 4-56
redrive assembly 4-57
smart contact assembly 4-58
system board 4-58
toner sensor 4-61
transfer roll assembly 4-61
upper front cover hinge assembly 4-62
upper paper deflector assembly 4-63
restore EP factory defaults 3-18
right cover removal 4-10
right side frame removal 4-22
ROM memory test 3-9

S
safety information xv
safety inspection guide 6-1
scheduled maintenance 6-1
screw identification table 4-6
SDRAM memory test 3-9
sensor tests, finisher 3-14
sensors
fuser exit sensor 4-28
fuser narrow media sensor 4-28
input 4-34
output bin sensor, integrated paper tray 2-72
paper bin full 4-54
paper size sensing board 4-41
toner 4-61
service checks
5-bin mailbox 2-38
900 error code 2-41
950 error code 2-42
charge roll 2-43
cover closed switch/cable 2-44
cover open switch/cable 2-44
dead machine 2-45

duplex option 2-47
envelope feeder 2-49
fuser 2-52
fuser solenoid 2-55
high-capacity feeder input tray 2-56
high-capacity output stacker 2-62
input sensor 2-64
input tray, optional 2-64
internal tray card/paper size sensing 2-66
main drive 2-68
main fan 2-69
operator panel 2-70
options 2-71
output bin sensor 2-72
output expander 2-72
paper feed 2-76
parallel port 2-77
print quality 2-78
printhead 2-78
smart contact assembly 2-85
StapleSmart finisher 2-86
toner sensor 2-93
transfer roll 2-94
service error codes 2-2
shield
inner 4-34
outer 4-52
smart contact assembly removal 4-58
specifications
environment 1-7
media 1-8
power and electrical 1-6
printer 1-5
speed and performance 1-3
StapleSmart finisher
locations 5-8
parts catalog 7-79
service check 2-86
tests
feed tests 3-14
sensor tests 3-14
start 2-1
sub error codes 2-5
9xx and 2xx codes 2-5
base printer 2-6
base printer (fuser) 2-11
variable values 2-6
switch, cover closed 2-44, 4-19
symptoms
base printer 2-35
duplex option 2-36
envelope feeder 2-36
high-capacity feeder 2-35

Index

I-5

4060-xxx

output expander option 2-36
paper trays 2-36
StapleSmart finisher 2-37
system board
connectors 5-10, 5-11
installation 4-60
parts catalog 7-30
removal 4-58

T
toner sensor removal 4-61
tools 1-14
transfer roll assembly
parts catalog 7-26
removal 4-61
service check 2-94

U
unique tools 1-14
upper front cover hinge assembly removal 4-62
upper front cover removal 4-12
upper paper deflector 4-63
user attendance messages 2-19
user line 2 link messages 2-32
user status displays 2-14
user status messages 2-17

V
vertical paper adapter 7-74
viewing the permanent page count 3-17

W
warning messages (user status displays) 2-16

I-6 Service Manual

4060-xxx

Part number index
P/N

Description

Page

1332514 Power cord set, 8 ft. - Bolivia (HV), Peru (HV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1339537 Power cord set - Ireland, U.K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1339538 Power cord set - Austria, Belgium, BlueMark, Catalan, CIS, Czechoslovakia, Finland, France,
Germany, Greece, Hungary, Italy, Netherlands, Norway, Poland, Portugal, Russia, Slovak countries,
Spain, Sweden, Turkey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1339539 Power cord set - Israel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1339540 Power cord set - Switzerland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1339541 Power cord set - Botswana, Lesotho, Namibia, Pakistan, South Africa . . . . . . . . . . . . . . . . . . . . 7-29
1339543 Power cord set - Denmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1339545 Power cord set, 8 ft. right angle - Argentina (HV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1339549 Power cord set - Brazil (HV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1339551 Power cord set - Brazil (LV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1339552 Power cord set–Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1342530 Power cord set - Paraguay (HV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
1342534 Power cord set, 8 ft. - Chile, Uruguay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
13A0296 Cable, Twinax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
13A0297 Cable, Coax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
13A0298 Cable, serial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
43H5248 Power cord set,–USA, Canada, Columbia, Costa Rica, Dominican Republic, El Salvador, Ecuador,
Guatemala, Honduras, Mexico, Nicaragua, Panama, Puerto Rico, Saudi Arabia, Taiwan (LV)
Venezuela, Virgin Islands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
43H5546 Power cord set - PRC (HV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
56P0161 Cable assembly, SER+PAR 1284C INA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
56P0161 INA, serial and parallel C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P0162 Adapter, parallel 1284 C-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P0162 Cable, parallel 1284 C-B adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
56P0556 Card assembly, 2000 tray option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
56P0557 Board, option tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45
56P0695 8MB memory option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P0696 16MB memory option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P0697 32MB memory option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P0698 64MB memory option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P0699 128MB memory option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1100 Cartridge, empty shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1101 Cable assembly, 6’ parallel, A-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
56P1300 Cover, fuser wick assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1301 Cover assembly, laser assembly, 250-sheet output, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1302 Cover assembly, laser assembly, 500-sheet output, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . 7-3
56P1303 Upper front cover with labels w/Lexmark logo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1305 Hinge, upper front cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1306 Cover, right side, 250-sheet output, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1307 Cover, right side 500-sheet output, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1308 Latch, upper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1309 Cover assembly, lower front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1310 Operator panel assembly 110V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1311 Operator panel assembly 220V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1314 Shroud, fan, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Part number index

I-7

4060-xxx

56P1315 Shroud, fan, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
56P1316 Flag, output paper level, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
56P1317 Duct, left stacker, 250-sheet, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
56P1318 Duct, main cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
56P1319 Support, right stacker plate, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
56P1320 Right side frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
56P1321 Left side frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
56P1322 Frame, EP module, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
56P1323 Flag, paper out 500-sheet tray, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
56P1324 Flag, paper out 250-sheet tray, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
56P1325 Pick arm assembly (500-sheet) 200⁄ 210⁄ 400⁄ 410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35
56P1325 Pick arm assembly (500-sheet), 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
56P1326 Pick arm assembly (250-sheet) 000⁄ 010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35
56P1326 Pick arm assembly (250-sheet), 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
56P1327 Alignment assembly paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
56P1328 Redrive assembly, 500 in/500 out, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
56P1330 Gearbox, w/motor, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
56P1331 Parts packet, bellcrank and spring for 500 tray, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . .7-13
56P1332 Gearbox, w/motor, 200/210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
56P1333 Fuser assembly w/115V lamp, 000/010/200/210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
56P1334 Deflector, inner, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
56P1335 Fuser assembly w/220V lamp, 000/010/200/210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
56P1336 Deflector, inner, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
56P1337 Parts packet, bellcrank and spring for 250 tray, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13
56P1338 Fuser assembly w/100V lamp, 000/010/200/210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
56P1339 Interconnect board assembly 2 slot, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P1340 Interconnect board assembly 1 slot, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P1341 Cover, INA flat (blank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
56P1342 Shield, inner assembly, 2 slot, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
56P1343 Shield, inner assembly, 1 slot, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
56P1344 Shield, outer 2 slot, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
56P1345 Shield, outer 1 slot, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
56P1346 Parts packet, reference adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
56P1347 Frame, EP module, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5
56P1348 Kit, fuser cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
56P1349 Clip, reference ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
56P1350 Board, input tray (ITC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
56P1352 MPF pad/separator arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
56P1356 Cover, clear bezel, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
56P1357 Transfer roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
56P1358 Cover, clear bezel, 200/210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
56P1360 Fan, main w/cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7, 7-35
56P1361 Toner sensor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
56P1362 Lamp, 115V, 000/010/200/210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
56P1363 Lamp, 220V, 000/010/200/210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
56P1364 Fuse, for 220 V ac LVPS 6.3 a/250V, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
56P1365 Fuse, for 110 V ac LVPS 5 a/250V, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
56P1366 Fuse, for 110 V ac LVPS 10 a/250V, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
56P1367 Fuse, for 220 V ac LVPS 3.15 a/250V, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
56P1369 LVPS, 110 V ac, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
56P1371 LVPS, 110 V ac, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
56P1372 LVPS, 220 V ac, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
56P1374 LVPS, 220 V ac, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
56P1375 Power supply, high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29

I-8 Service Manual

4060-xxx
56P1382 Int. card/autocomp card cable (paper low/out sensors) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13, 7-35
56P1383 Cable, autoconnect bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
56P1384 Cable, main drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
56P1385 Cable, front harness (HVPS/input sensor/toner sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
56P1385 Cable, front harness (HVPS⁄ input sensor⁄ toner sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
56P1386 Cable, laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10, 7-11, 7-12, 7-39
56P1387 Cable, HSYNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10, 7-11, 7-12, 7-39
56P1388 Cable, mirror motor, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10, 7-39
56P1389 Cable, deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
56P1390 Cable, system board to fuser board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
56P1391 Sensor, standard bin level with cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7, 7-35
56P1394 Cable assembly, operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3, 7-37
56P1395 Switch, cover closed w/cable assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1395 Switch, cover open w/cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
56P1396 Printhead assembly (includes all cables), 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
56P1398 Sensor, MPF cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
56P1399 Smart cartridge contact assembly w/cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1399 Smart contact assembly w⁄ cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
56P1400 Autoconnect top, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
56P1401 Autoconnect top, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
56P1402 Narrow media sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
56P1402 Sensor, narrow media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
56P1403 Exit sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
56P1403 Sensor, exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
56P1405 Cable, AC fuser lamp to LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
56P1406 Card asm, paper wt/paper low sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
56P1408 Cartridge fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7, 7-35
56P1409 115 V Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
56P1412 220 V Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
56P1413 100 V Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
56P1414 250 duplex assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
56P1415 Wiper assembly, wet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
56P1416 500 duplex assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-49
56P1417 16MB Flash card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1418 32MB Flash card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1419 Hard disk, with adapter 20+GB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1424 Optra Forms hard disk, with adapter (20+GB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1427 Optra Forms 32MB Flash card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
56P1428 Optra Forms 16MB Flash card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
56P1429 Simplified Chinese font card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
56P1430 Traditional Chinese font card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
56P1435 Serial adapter, int w/out +5 V ac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1436 RS232C serial interface card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1437 Parallel 1284-B interface card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1438 Japanese font card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87
56P1443 Printhead assembly (includes all cables), 200/210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
56P1444 Card assembly, communications, non-network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
56P1445 Card assembly, communications, network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
56P1741 MarkNet N2100t token ring internal print server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1742 MarkNet N2101e Ethernet 10BaseT/100Base TX internal print server . . . . . . . . . . . . . . . . . . . . 7-86
56P1743 MarkNet N2104fl-SC fiber optic (10MB) internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1744 MarkNet N2103fx-SC fiber optic (100MB) internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
56P1747 System card assembly, stapler option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
56P1753 Kit, operator panel overlay-English, Brazilian Portuguese, French, and Spanish . . . . . . . . . . . . . . 7-3

Part number index

I-9

4060-xxx

56P1754 Kit, operator panel overlay-Dutch, French, German, and Italian . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
56P1755 Kit, operator panel overlay-Czech and Hungarian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
56P1756 Kit, operator panel overlay-Danish, Finnish, Norwegian, and Swedish . . . . . . . . . . . . . . . . . . . . . .7-3
56P1757 Kit, operator panel overlay-Polish, Russian, and Turkish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
56P1758 Kit, operator panel overlay-WW English and Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
56P1759 Kit, operator panel overlay-WW English, Simplified Chinese, Traditional Chinese, and Japanese 7-3
56P1850 Card assembly, Bar Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
56P1850 Card assembly, Bar code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P1851 Card assembly, PrintCryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P1851 PrintCryption card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
56P1854 Printhead assembly (includes all cables), 400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
56P1855 115 V Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
56P1856 220 V Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
56P1857 100 V Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
56P1858 Gearbox, w/motor, 400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
56P1859 Fuser assembly w/115V lamp, 400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
56P1860 Fuser assembly w/220V lamp, 400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
56P1861 Fuser assembly w/100V lamp, 400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
56P1862 Cover, clear bezel, 400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
56P2122 Cover, left door, 250 1-slot, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
56P2126 Cover, left door, 500 2-slot, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
56P2136 Gear, bevel with grease packet and washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
56P2182 Card assembly, ImageQuick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31, 7-86
56P2404 Shield, INA flat non-network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
56P2405 Shield, INA flat network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
56P2407 MPF frame assembly with solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
56P2407 MPF solenoid w/cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37
56P2410 System board assembly (non-network), 000 includes 56P1444 . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P2411 System board assembly (network), 010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P2412 System board assembly (non-network), 200 includes 56P1444 . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P2413 System board assembly (network), 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P2414 System board assembly (non-network), 400 includes 45P1444 . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P2415 System board assembly (network), 410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
56P2468 Card assembly IPDS and SCS/TNe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
56P2468 Card assembly, IPDS and SC5/TNe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
7371454 Relocation kit, 250/250-sheet printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
7371455 Relocation kit, 500/250-sheet printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A0004 Spring, latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
99A0007 Label, TLI/ID/serial number - blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
99A0026 Tray bias arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7, 7-41, 7-45
99A0028 Spring, tray bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A0039 Roller, developer support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A0052 Shaft asm, stacker lower exit upper stacker asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58
99A0052 Shaft assembly, lower exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53
99A0053 Sensor, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A0058 Pad, base 500-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
99A0058 Pad, machine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
99A0062 Bracket, level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A0063 Paper switch actuate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A0063 Spring, switch activate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45
99A0070 Pick roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13, 7-41, 7-45
99A0070 Roll assembly, pick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-73
99A0071 Arm assembly, MPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
99A0073 Screw, damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15

I-10 Service Manual

4060-xxx

99A0074 Bushing, pick roll shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
99A0075 Screw, socket set M4X5 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
99A0076 Pick roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
99A0079 Tray assembly, backup roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0081 Spring assembly, separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
99A0083 Parts kit, multipurpose tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0084 Flag, MPT paper out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
99A0085 Tray, backup roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0086 Roller, backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0087 Spring, backup roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0088 Cover, backup tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0104 Spring, upper diverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53, 7-58, 7-61, 7-83
99A0107 Deflector, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
99A0119 Wear strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19, 7-43
99A0120 Restraint pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19, 7-21, 7-43, 7-45
99A0121 Clip, 250-sheet tray wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19, 7-43
99A0122 Shaft assembly, drive roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0124 Plate, snap-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19, 7-21, 7-43, 7-45
99A0125 Frame assembly, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
99A0126 Finger, autosize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19, 7-21, 7-43, 7-45
99A0127 Slider, autosize 250-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19, 7-43
99A0134 Shaft, power takeoff 250, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
99A0137 Frame assembly, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
99A0181 Spring, transfer roll left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
99A0184 Spring, transfer roll right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
99A0185 Shaft, transfer pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
99A0188 Guide, rear paper, use with 99A0219 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
99A0197 Shaft, drive rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0208 Parts packet, pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77, 7-88
99A0219 Frame assembly, top with labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
99A0226 Guide, paper exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
99A0231 Bail, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0232 Cover, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0234 Parts packet, screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A0234 Parts packet, screw - kiosk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0240 Parts packet, retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
99A0263 Parts packet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53, 7-58, 7-61
99A0263 Parts packet, screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5, 7-7, 7-9, 7-41
99A0263 Parts packet, screw (alignment asm mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
99A0263 Parts packet, screw (auto comp assembly mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
99A0263 Parts packet, screw (auto comp mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45
99A0263 Parts packet, screw (board mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
99A0263 Parts packet, screw (bracket 250-sheet frame retention mounting) . . . . . . . . . . . . . . . . . . . . . . . 7-73
99A0263 Parts packet, screw (charge roll) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
99A0263 Parts packet, screw (clip ref ground mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
99A0263 Parts packet, screw (deflector mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
99A0263 Parts packet, screw (developer drive ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
99A0263 Parts packet, screw (frame mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15, 7-71
99A0263 Parts packet, screw (gearbox mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
99A0263 Parts packet, screw (hanger) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
99A0263 Parts packet, screw (INA cover mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
99A0263 Parts packet, screw (inner shield mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
99A0263 Parts packet, screw (laser cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
99A0263 Parts packet, screw (left side cover mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Part number index I-11

4060-xxx

99A0263 Parts packet, screw (lower deflector mounting 12 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
99A0263 Parts packet, screw (lower deflector mounting 8 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
99A0263 Parts packet, screw (motor mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
99A0263 Parts packet, screw (option board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
99A0263 Parts packet, screw (outer shield mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
99A0263 Parts packet, screw (printhead mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10, 7-11, 7-12
99A0263 Parts packet, screw (right side cover mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
99A0263 Parts packet, screw (switch spring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
99A0263 Parts packet, screw (tray option card mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-71
99A0263 Parts packet, screw (upper front cover mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
99A0263 Parts packet, screw (wear plate mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45
99A0263 Parts packet, screw(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
99A0263 Parts packet, screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25, 7-31, 7-81, 7-83
99A0263 Screw, parts packet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
99A0263 Screw, USB attaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
99A0267 Parts packet, clip (pick roll shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
99A0267 Parts packet, retainer (aligner assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45, 7-71
99A0267 Parts packet, retainer (pivot shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
99A0267 Parts packet, retainer (roller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-71
99A0267 Parts packet, retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A0268 Parts packet, springs paper feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A0269 Parts packet, duplex option fan mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A0271 Parts packet, envelope option gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A0271 Parts packet, gear kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
99A0272 Shaft, 250-sheet drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-71
99A0273 Gear, bevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-47, 7-71
99A0274 Gear, feed roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45, 7-71
99A0275 Spring, power takeoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45, 7-71
99A0275 Spring, power takeoff shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
99A0276 500 Drive roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45, 7-71
99A0277 Wear plate, pass thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-71
99A0278 Bellcrank, roller release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43, 7-71
99A0279 Bearing, drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-47, 7-71
99A0280 Bearing, drive shaft low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45, 7-71
99A0280 Bushing, drive shaft low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
99A0281 Cable, 250-sheet autoconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-47, 7-71
99A0282 Cable, 250-sheet autoconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45
99A0286 Spring, backup roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43, 7-47, 7-71
99A0288 Sensor, option pass thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45
99A0288 Sensor, pass thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-73
99A0292 Strip, wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
99A0292 Wear strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
99A0299 Parts packet, duplex option cam follower assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A0349 Arm, transfer roll assembly right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
99A0350 Sensor, paper low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45
99A0351 Sensor, output expander pass thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55
99A0351 Sensor, stacker pass thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59
99A0361 Belt, 160 gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-55
99A0361 Belt, 160G upper stacker asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59
99A0362 Arm asm, belt idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59
99A0362 Arm assembly, belt idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55, 7-81
99A0363 Pulley, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55, 7-59, 7-83
99A0364 Spring, belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55, 7-59
99A0368 Shaft asm lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59

I-12 Service Manual

4060-xxx
99A0368 Shaft assembly, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55, 7-83
99A0369 Shaft asm, exit upper stacker asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
99A0369 Shaft assembly, exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
99A0371 Cover, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
99A0372 Cover, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
99A0382 Motor, stepper DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0384 Shaft, drive pressure roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0385 Cable, auto connect front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0388 Switch, envelope out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0389 Paper weight assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0390 Support, slide out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0392 Kit, door switch spring and bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
99A0393 Clutch, restraint/gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0394 Grease packet, Nyogel 744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0400 Spring, restraint roll shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0404 Parts packet, retainer (4 mm PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0404 Parts packet, retainer (6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0404 Parts packet, retainer (7 mm shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0404 Parts packet, retainer (clip 5 mm shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0404 Parts packet, retainers envelope option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0405 Pick arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
99A0409 Bracket, dual sensor mounting upper stacker asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
99A0409 Level sensor bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
99A0413 Parts packet, screw duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0413 Screw, top/motor/board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0414 Sensor asm, bin full dual upper stacker asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
99A0414 Sensor, dual bin full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
99A0415 Spring, swing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53, 7-58
99A0419 Spring, tray bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45
99A0426 Screws, parallel connector mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
99A0427 Label, envelope orientation icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0438 Bushing, drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43, 7-45
99A0445 Stud assembly, 250-sheet frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-71
99A0446 Aligner assembly, paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45, 7-71
99A0447 Shaft, 500-sheet drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
99A0448 Arm, paper out 250-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
99A0450 Retainer, roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-45
99A0451 Roll, skewed backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-71
99A0451 Roller, skewed backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
99A0452 Washer, frame mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47
99A0462 Grease packet, IBM #23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59, 7-63
99A0469 Deflector guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0481 Latch, output tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
99A0482 Spring, output tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
99A0484 Belt, gear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0485 Sensor, envelope pass thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0487 Flag, envelope out sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0488 Roller, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0489 Spring, latch return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0491 Bracket, stack limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0494 Spring, cam clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
99A0512 Parts kit, charge roll link asm, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27, 7-88
99A0513 Parts kit, charge roll link asm, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27, 7-88
99A0545 External serial adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86

Part number index I-13

4060-xxx

99A0548 Tie, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-85
99A0549 Shield, ESD assembly with label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A0556 Spring, counterbalance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A0567 Link, gear release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A0571 Cover, front control board with ESD brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53
99A0572 Parts packet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53, 7-58
99A0572 Parts packet, bearings, 500-sheet stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83, 7-88
99A0577 Parts packet, cable ties (10 each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3, 7-88
99A0585 Parts packet, contact kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7, 7-88
99A0627 Jumper, 2 pin (use with 99A1749) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59
99A0627 Jumper, pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
99A0629 Adapter card, SES for SCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
99A0650 Frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0651 Sensor assembly, paper out/upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0653 Switch, lower limit microswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0654 Switch, paper low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0655 Door assembly, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0656 Cover, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0657 Hinge, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0658 Magnet, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0659 Frame, printer support 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0660 Frame, printer support frame 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0661 Tray assembly, elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0662 Transfer leadscrew assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0663 Pulley, idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0664 Belt, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0667 Power supply board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0672 Parts packet, foot (stabilizer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A0675 Parts packet, screw (card asm. mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0675 Parts packet, screw (deflector mt 8-18 x 7/8 inch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0675 Parts packet, screw (door to door frame mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-71
99A0675 Parts packet, screw (feed frame clamp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0675 Parts packet, screw (printer support 2 frame mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0675 Parts packet, screw (wear plate mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-71
99A0675 Parts packet, screw high-capacity feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A0675 Parts packet, screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0676 Parts packet, nut (6-32 hinge mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0676 Parts packet, nut (door switch spring mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0676 Parts packet, nut support frame 1 hex, support frame 2, hex . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-71
99A0676 Parts packet, nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0676 Parts packet, nuts high-capacity feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A0677 Parts packet, washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
99A0677 Parts packet, washer (bracket 250-sheet frame retention mounting) . . . . . . . . . . . . . . . . . . . . . .7-73
99A0677 Parts packet, washer (card asm. mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0677 Parts packet, washer (door switch spring mounting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0677 Parts packet, washer (hinge mounting flat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0677 Parts packet, washer (hinge mounting star) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0677 Parts packet, washer (support frame 1 star, support frame 2 star) . . . . . . . . . . . . . . . . . . . . . . . .7-71
99A0677 Parts packet, washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A0677 Parts packet, washers high-capacity feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A0678 Deflector, base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-73
99A0679 Bracket, 250-sheet frame retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-73
99A0681 Strip, wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A0684 Cable, HCIT-14 pin flex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-71

I-14 Service Manual

4060-xxx

99A0685 Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
99A0687 Parts packet, mounting feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69
99A0690 Cable, optical sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
99A0691 Bearing, Nyliner leadscrew top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
99A0692 Base, 2000 option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
99A0695 Parts kit, paper size switch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
99A0698 Clamp, feed frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65, 7-67
99A0702 Printer stand caster, non-locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0703 Printer stand caster, locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0704 Printer stand grommet, wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0705 Printer stand lock, cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0706 Printer stand storage shelf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0707 Printer stand door assembly, cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0710 Printer stand filler, rear top piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0711 Printer stand table assembly, large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0712 Printer stand table assembly, small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
99A0714 Cover, power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
99A0715 Cable, low voltage power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
99A0716 Bearing, leadscrew bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
99A0717 Cable, paper low switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
99A0719 Clamp, top frame mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-67
99A0720 Cable, lower limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
99A0892 Restraint, side 250-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
99A0893 Restraint, back 250-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
99A0895 Restraint, side 500-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
99A0906 Frame assembly, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
99A0907 Frame assembly, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77
99A0912 Frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
99A0913 Shaft assembly, 40T middle stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A0913 Shaft assembly, middle 40T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
99A0913 Shaft, 40T middle output stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
99A0914 Drive asm, output stacker DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
99A0914 Output expander assembly, mechanical linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
99A0915 Board, output expander DC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53
99A1017 Roll assembly, charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
99A1054 Pick arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
99A1055 Arm assembly, pick 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
99A1512 Cover assembly, redrive cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
99A1512 Cover, redrive cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1517 Frame extension, left, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
99A1518 Frame extension, right, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
99A1524 Cartridge load spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
99A1525 Deflector, upper PF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
99A1531 MPF lower deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
99A1536 Tray assembly, 250-sheet option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43
99A1536 Tray, integrated 250-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
99A1537 Knob, paper size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43, 7-45
99A1538 Contact, RSF ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
99A1540 Nut plate, frame extension, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
99A1541 Clip, external ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
99A1544 Developer drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
99A1546 Shield, gear #60/MPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
99A1555 Bushing, charge roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
99A1569 Shaft, power takeoff 500, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Part number index I-15

4060-xxx

99A1576 Tray assembly 500-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
99A1576 Tray assembly, 500-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
99A1578 Arm, transfer roll left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
99A1580 Flag, output paper level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53
99A1582 Slider, autosize 500-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21, 7-45
99A1583 Plate, 500-sheet tray wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21, 7-45
99A1587 Support, paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
99A1594 Retainer, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3
99A1596 Contact, LSF ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
99A1601 Latch, back restraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19, 7-21, 7-43, 7-45
99A1602 Restraint, back 500-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
99A1605 Kit, cap⁄ stack bails 500-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
99A1611 Shield, Ethernet (blank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33
99A1613 Flag, bin full dual sensor upper stacker asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58
99A1613 Flag, output paper level, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
99A1633 Parts packet, screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-88
99A1636 Base, 500-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45
99A1638 Base, 250-sheet option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41
99A1644 Door assembly, redrive 250 sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
99A1645 Arm, paper out 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47
99A1646 Arm assembly, pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A1647 Rib assembly, 250-sheet special media tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
99A1654 Tray, universal adjustable 250-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
99A1658 Cover, fuser wiper cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25
99A1664 Bellcrank, roller release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47
99A1665 Deflector, base 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47
99A1666 Label, options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45, 7-51, 7-53, 7-57, 7-61, 7-73
99A1666 Label, tray options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41, 7-79
99A1667 Bracket, 500-sheet tray retention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47
99A1687 Stop asm, paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
99A1688 Arm, diverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58
99A1688 Diverter arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53
99A1689 Clutch asm, output stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58
99A1689 Spring clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53
99A1690 Belt, 95G lower stacker asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58
99A1694 Guide, edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
99A1696 Cover, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
99A1697 Cover, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
99A1698 Cover, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
99A1699 Guard, pass thru sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
99A1700 Board assembly, electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-51
99A1701 Tray asm, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57
99A1702 Stud assembly, 500 frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47
99A1704 Gear, idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A1705 Gear, idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A1706 Tray assembly, drive roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-75
99A1707 Tray assembly, drive roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-77
99A1708 Cover, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
99A1709 Cover, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
99A1710 Cover, wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
99A1711 Cover, top bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
99A1712 Tray, paper cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
99A1713 Support, paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61
99A1714 Door, rear access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61

I-16 Service Manual

4060-xxx

99A1715 Roller asm, rear access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1716 Drive asm, main DC drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1717 Gear, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63, 7-83
99A1718 Cable asm, lower auto connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1719 Cable asm, upper auto connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1720 Bracket, attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1721 Deflector, paper top bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1722 Deflector, paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1723 Shaft asm, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1724 Shaft asm, drive w/gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1725 Packet, drive shaft bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1726 Frame asm, left w/clutch asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1727 Frame asm, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1728 Cam, diverter actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1729 Latch, diverter actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1730 Arbor, diverter actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1731 Spring, diverter actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1732 Solenoid, diverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1734 Spring, static ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1735 Flag, bin full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1736 Cable, dual sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1737 Sensor, dual paper height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1738 Deflector, paper exit w/brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1739 Bracket asm, bail attach w/brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1740 Board asm, 5-bin mailbox system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1741 Spring, diverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1742 Sensor, 5-bin mailbox pass thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1743 Kit, 5-bin mailbox asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1743 Parts packet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1744 Kit, high-capacity output stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1745 Cover, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1746 Cover, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1747 Cover, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1748 Door asm, rear access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1748 Door assembly, rear access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55
99A1749 Board asm, high-capacity output stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
99A1750 Wear plate, pass thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45
99A1751 Switch asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
99A1751 Switch asm, tray sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1777 Flag, tray sensing switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1778 Pulley, output tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1779 Spring, output tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1780 Gear, damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1781 Frame, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1782 Shaft, pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1783 Frame, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1784 Bracket, attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53, 7-58
99A1785 Latch, rear access door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61, 7-79
99A1785 Latch, rear door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
99A1786 Gear, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
99A1787 Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1788 Retainer, R-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1789 C-clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
99A1790 Guide, output tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

Part number index I-17

4060-xxx

99A1791 Stacker asm, paper path lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59
99A1792 Stacker, asm paper path upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59
99A1793 Parts packet, screw w/washer (motor mt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1794 Parts packet, nut and washer (drive pulley plate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1795 Motor assembly, DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1796 Belt, DC motor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1797 Idler pulley, belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1798 Plate, drive pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1799 AC receptacle, lower AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1800 Pulley, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1801 Retainer, C-clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1802 AC receptacle, upper AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1803 Cover, top LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1804 Nut w/lock washer, top LVPS cover mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1805 Grommet, top LVPS cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-69
99A1806 Card assembly, 2000 option control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A1807 Cable, AC internal wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A1808 Cord, AC external jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-67
99A1812 Label, tray option number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19, 7-21, 7-73
99A1817 Tray, output expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53
99A1818 Strip, wear dimple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-65
99A1819 Mounting, frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77
99A1820 Belt, 185G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75, 7-77, 7-81
99A1829 Label, tray option number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43, 7-45, 7-65
99A1857 Deflector, upper redrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-53
99A1857 Upper redrive deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A1890 Tray assembly, 250-sheet special media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
99A1894 Restraint, side 250-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
99A1895 Restraint, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
99A1928 Spring, bellcrank 250-sheet tray option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43
99A1929 Spring, bellcrank 500-sheet option tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47
99A1952 Label, paper size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43, 7-45
99A2016 Duct, left stacker, 500-sheet, 200/210/400/410 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
99A2017 Guide, extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
99A2018 Support, left lower stacker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A2019 Spring, cartridge hold down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A2020 Transfer plate assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A2021 Support, right stacker plate, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A2071 Sensor, MPF paper out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
99A2076 Pan, drip ITC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A2077 Pad, machine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A2078 Pan, motor drip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A2081 Parts packet, developer drive shaft, coupler gear #55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
99A2093 Restraint, back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
99A2151 Redrive assembly, 250 in/250 out, 000/010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A2160 Restraint, back 250-sheet tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
99A2409 Parts packet, retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-77
99A2445 Guard, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
99A2480 Kit, maintenance StapleSmart wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-85
99A2485 Tray assembly, UAT 400-sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86
99A2500 Cover, left base assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-79
99A2501 Cover, right base assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-79
99A2502 Switch, stapler access door assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-79
99A2503 Cover, stapler access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-79

I-18 Service Manual

4060-xxx

99A2504 Cable assembly, left stapler bin level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
99A2505 Cover, top assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2506 Top cover bail/plate, right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2507 Top cover bail/plate, left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2508 Kit, stacking bail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2509 Parts packet, screws, switch (stapled access) mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2510 Clip, brush ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2511 Bail, center stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2512 Door, rear access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2513 Motor assembly, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2515 Shaft assembly, upper drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2516 Deflector, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2517 Shaft assembly, upper exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2518 Shaft assembly, lower exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2519 Cover, accumulator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2520 Tray, output assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2521 Sensor, stapler bin empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2523 Spring, output tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81, 7-83
99A2524 Cable, stapler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
99A2525 Sensor, stapler pass thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
99A2526 Stapler assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
99A2527 Frame assembly, left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2528 Frame assembly, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
99A2529 Guide, inner bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2530 Cable assembly, right stapler bin level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
99A2531 Switch assembly, top cover open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2532 Cable, ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
99A2533 Bar, upper output tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81, 7-83
99A2534 Ground cable, stapler tray bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
99A2538 Belt, FHT 86T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2539 Flange, pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2540 Bearing, redrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2541 Sensor cover, stapler bin empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2542 Tray, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79
99A2543 Cover, optical sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81, 7-83
99A2544 Card assembly, right stapler bin level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
99A2545 Spring, swing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
99A2546 Label, pinch point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
99A2547 Pulley, belt idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2548 Bumper, output tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81, 7-83
99A2549 Card assembly, left stapler bin level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2551 Clutch assembly, stapler option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2552 Bushing, tensioner CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83
99A2556 Bracket, attach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
99A2557 Clip, static ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81
99A2559 Paper alignment wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85
99A2575 Stapler cartridge holder 321-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81

Part number index I-19

4060-xxx

I-20 Service Manual



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Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.4
Linearized                      : Yes
Subject                         : Lexmark T63x
Modify Date                     : 2004:03:31 14:46:06-05:00
Create Date                     : 2004:03:17 16:32:45Z
Page Count                      : 345
Creation Date                   : 2004:03:17 16:32:45Z
Mod Date                        : 2004:03:31 14:46:06-05:00
Producer                        : Acrobat Distiller 5.0.5 (Windows)
Author                          : Lexmark International, Inc. D22A/mkc
Metadata Date                   : 2004:03:31 14:46:06-05:00
Creator                         : Lexmark International, Inc. D22A/mkc
Title                           : 4060-xxx Service Manual (P/N 12G9221)
Description                     : Lexmark T63x
Page Mode                       : UseOutlines
Page Layout                     : SinglePage

EXIF Metadata provided by EXIF.tools