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Dell 5210n, 5310n Service Manual 14Jan2010...
Page 3: Table Of Contents

Table of contents Laser notices ............xi Safety information .
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Symptom tables ..............2-5 Base printer symptoms .
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Signature button assembly service check ..........2-1 23 StapleSmart finisher service check .
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Model Name ..............3-20 Configuration ID .
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202 Paper Jam Open Rear Door ..........3-43 23x Paper Jam Open Duplex Rear Door .
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MPF solenoid assembly removal ........... .4-63 Operator panel board removal .
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Assembly 16: Electronics—shields ........... 7-32 Assembly 17: Cabling diagrams 1 .
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Linking trays ............... A-17 Identifying and linking output bins .
Page 11: Laser Notices

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.
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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.
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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.
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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...
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Japanese Laser Notice Laser notices...
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Korean Laser Notice Service Manual...
Page 17: Safety Information

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 •...
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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 •...
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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 •...
Page 20: Preface

Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.
Page 21: General Information

1. General information The Dell 5210n and 5310n laser printers are letter quality page printers designed to attach to IBM-compatible personal computers and to most computer networks. The Dell 5210n and 5310n laser printers are available in the following models:...
Page 22: Options

250- and 500-sheet paper drawers – 400-sheet universally adjustable tray – 2000-sheet high-capacity feeder – Envelope feeder – Duplex option—250-sheet – Duplex option—500-sheet (For Dell 5210n and Dell 5310n) – Output expander – High-capacity output stacker – StapleSmart™ Finisher – 5-bin Mailbox –...
Page 23: Configured Models

CAUTION: Floor-mounted configurations require furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet drawer. Certain other configurations also must have a printer stand or printer base. More information is available on our Dell Web site at www.dell.com. General information...
Page 24: Specifications

Specifications Resolution 1200 1200 dpi • 2400 Image Quality • 1200 Image Quality • 600 x 600 dpi • Data streams PostScript 3 emulation • PCL 6 emulation • PPDS migration tool • PDF v1.5 emulation • Print speed and performance print speed Performance Performance speed depends on: Interface to the host (USB, serial, parallel, network)
Page 25: Memory Configuration

Depending upon the options and features used, additional memory may be required to optimize performance. Available memory options Optional 128MB, 256MB, and 512MB SDRAM DIMMs are available from Dell. The memory options are 168-pin synchronous DRAM DIMMs. Flash memory options include 32MB and 64MB.
Page 26: Dimensions

Dimensions Description Height Width Depth Weight Printer Dell 5210n (base printer) 16.0 in. 17.2 in. 20.2 in. 51.6 lb (406 mm) (436 mm) (513 mm) (23.1 kg) Dell 5310n (base printer) 16 in. 17.2 in. 20.2 in. 51.6 lb (406 mm)
Page 27: Power Requirements

Power requirements Average nominal power requirements for the base printer configuration (110 volt). Power levels are shown in watts (W). Maximum current is given in Amperes (A). Dell 5210n Dell 5310n Printing states .05W .05W Off (all models) Idle—average power...
Page 28: Environment

All measurements are made in accordance with ISO 7779 and conform with ISO 9296. 1 Meter average Declared sound Model Status sound pressure power Dell 5210n Idle (standby mode) 32 dBA 4.7 Bels Simplex printing 54 dBA 6.8 Bels Duplex printing...
Page 29: Media Specifications

For more details about the types of paper and specialty media your printer supports, refer to the Card Stock & Label Guide available on the Dell Web site at www.dell.com. We recommend that you try a limited sample of any paper or specialty media you are considering using with the printer before purchasing large quantities.
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Print media sizes (continued) Print media Dimensions size (UAT — universally (3— indicates adjustable tray) support) Executive 184.2 x 266.7 mm ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ (7.25 x 10.5 in.) Folio 216 x 330 mm ✓...
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Print media sizes (continued) Print media Dimensions size (UAT — universally (3— indicates adjustable tray) support) Other 98.4 x 162 mm ✓ ✓ ✓ ✓ ✓ Envelope to 176 x 250 mm (3.87 x 6.38 in. to 6.93 x 9.84 in.) This size does not appear in the Paper Size menu until Tray Size Sensing is turned off.
Page 32: Index

Printing label applications on your printer requires a special label fuser cleaner which prevents duplexing. 28 lb envelopes are limited to 25% cotton content. Includes envelopes fed from the multipurpose feeder only. Information on whether your vinyl label converter has passed Dell's criteria is available at www.dell.com. Service Manual 1-12...
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Printing label applications on your printer requires a special label fuser cleaner which prevents duplexing. 28 lb envelopes are limited to 25% cotton content. Includes envelopes fed from the multipurpose feeder only. Information on whether your vinyl label converter has passed the Dell’s criteria is available at www.dell.com. General information 1-13...
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Media sizes supported in the finisher Finisher output support Dimensions Size Standard Offset Stapled 210 x 297 mm ✓ ✓ ✓ (8.27 x 11.7 in.) 148 x 210 mm (5.83 x 8.27 in.) JIS B5 182 x 257 mm ✓ (7.17 x 10.1 in.) Letter 215.9 x 279.4 mm...
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Media weights supported in the finisher Finisher media weight Print media Type Standard Offset Stapled Paper Xerographic or 60 to 176 g/m 60 to 90 g/m 60 to 90 g/m business paper (16 to 47 lb bond) (16 to 24 lb bond) (16 to 24 lb bond) Card Index Bristol...
Page 36: Selecting Print Media

For detailed information, refer to the Card Stock & Label Guide located on the Dell Web site at www.dell.com. The laser printing process heats paper to high temperatures of 225°C (437°F) for Magnetic Ink Character Recognition (MICR) applications, and 205°C (401°F) for non-MICR applications.
Page 37: Transparencies

For detailed information, refer to the Card Stock & Label Guide, which is available on the Dell Web site at www.dell.com. Transparencies can be fed automatically from the multipurpose feeder and all standard and optional trays, except the 2000-sheet drawer.
Page 38: Labels

For detailed information on label printing, characteristics, and design, refer to the Card Stock & Label • Guide available on the Dell Web site at www.dell.com. Note: Labels are one of the most difficult print media for laser printers. All printer models require a special fuser cleaner for label applications to optimize feed reliability.
Page 39: Card Stock

Portrait orientation is preferred, especially when printing bar codes. • Do not use labels that have exposed adhesive. • Card stock Card stock is single ply, and has a large array of properties, such as the moisture content, thickness, and texture, that can significantly affect print quality.
Page 40: Avoiding Jams

Avoiding jams Use appropriate print media (paper, transparencies, labels, and card stock) to help ensure trouble-free printing. for more information. “Supported print media” on page 1-9 Note: Try a limited sample of any print media you are considering using with the printer before purchasing large quantities.
Page 41: Acronyms

Acronyms BLDC Brushless DC motor Customer Replaceable Unit Customer setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Digital multimeter Enhanced Data Out EEPROM Electrically Erasable Programable Read-Only Memory Electrophotographic process EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HCIT...
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Service Manual 1-22...
Page 43: Diagnostic Information

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.
Page 44: Understanding The Printer Operator Panel

Understanding the printer operator panel The operator panel on your printer is a 4-line back-lit gray scale display that can show both graphics and text. The Back, Menu, and Stop buttons are located to the left of the display, the navigation buttons are located below the display, and the numeric pad is located to the right of the display.
Page 45: Understanding The Menus

Operator panel (continued) Button Function The numeric pad consists of numbers, a pound '#' sign, and a backspace button. Numeric pad The 5 button has a raised bump for non-visual orientation. The numbers are used to enter numeric values for items like quantities or PINs. The backspace is used to delete the number to the left of the cursor.
Page 46: Power-on Self Test (post) Sequence

Power-On Self Test (POST) sequence 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: The LED turns comes on. The operator panel turns on. A partial row of pixels are displayed.
Page 47: Symptom Tables

Symptom tables Base printer symptoms Symptom Action Dead machine Go to “Dead machine service check” on page 2-80. Operator panel—one or more buttons do Go to “One or more operator panel buttons fail” on not work. page 2-107. Operator panel—none of the buttons work. Go to “No buttons work”...
Page 48: Paper Tray Symptoms

Paper tray symptoms Symptom Action Paper feed problem with 250-Sheet Paper Go to “Input tray(s) service check” on page 2-103. Tray. Paper feed problem with 500-Sheet Paper Go to “Input tray(s) service check” on page 2-103. Tray. Media fails to pass through from the lower Go to “Input tray(s) service check”...
Page 49: Staplesmart Finisher

StapleSmart finisher Symptom Action Finisher does not staple. Go to “StapleSmart finisher service check” on page 2-124. Printer does not recognize StapleSmart Go to “StapleSmart finisher service check” on page 2-124. Finisher Option as being installed. Close Top Cover displayed. Unable to clear Go to “StapleSmart finisher service check”...
Page 50: Messages And Error Codes

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 codes (9xx.xx) Error Description Possible causes Action code codes RIP Software...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll took too long to • Bad thermistor, circuit or cabling. Go to “920.xx—Cold fuser heat up after service check” on page 2-87. • Fuser not receiving sufficient AC transitioning to new power.
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll fell too far below • Bad thermistor, circuit, or cabling. Go to “920.xx—Cold fuser the desired temperature service check” on page 2-87. • Noisy thermistor signal. while printing.
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll fell too far below • Bad thermistor, circuit, or cabling. Go to “920.xx—Cold fuser the desired temperature service check” on page 2-87. • Noisy thermistor signal. while printing.
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll fell too far below • Bad thermistor, circuit, or cabling. Go to “920.xx—Cold fuser desired temperature service check” on page 2-87. • Noisy thermistor signal. while printing. Fuser •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll fell too far below • Bad thermistor, circuit, or cabling. Go to “920.xx—Cold fuser the desired temperature service check” on page 2-87. • Noisy thermistor signal. while printing.
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll fell too far below • Bad thermistor, circuit, or cabling. Go to “920.xx—Cold fuser desired temperature service check” on page 2-87. • Noisy thermistor signal. while printing. Fuser •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll fell too far below • Bad thermistor, circuit, or cabling. Go to “920.xx—Cold fuser desired temperature service check” on page 2-87. • Noisy thermistor signal. while printing. Fuser •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll reached final • Low wattage or incorrect lamp. Go to “922.xx—Cold fuser lamp detection check” on page 2-89. • Bad thermistor, circuit, or cabling. temperature but took •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll did not reach • Low wattage or incorrect lamp. Go to “922.xx—Cold fuser operating temperature in check” on page 2-89. • Bad thermistor, circuit, or cabling. time (new enhanced •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll took too long to • Low wattage or incorrect lamp. Go to “922.xx—Cold fuser reach the beginning check” on page 2-89. • Bad thermistor, circuit, or cabling. lamp detection •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll timed out in • Low wattage or incorrect lamp. Go to “922.xx—Cold fuser trying to reach the final check” on page 2-89. • Bad thermistor, circuit, or cabling. lamp detection •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Hot roll did not reach • Low wattage or incorrect lamp. Go to “922.xx—Cold fuser operating temperature in check” on page 2-89. • Bad thermistor, circuit, or cabling. time (new enhanced •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Fuser over temperature. • Short in the thermistor circuit. Go to “923.xx—Hot fuser Fuser page count service check” on page 2-90. • Noisy thermistor signal between 0 and 99,999. •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Open thermistor check • Noisy thermistor signal. Go to “924.xx—Hot fuser failure. Fuser page service check” on page 2-91. • Intermittent connection. count between 400,000 • Thermistor cable not connected or and 499,999.
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Too hot to do lamp Attempting to POR machine after Go to “925.xx—Hot fuser detection and NVRAM receiving a 925.01. service check” on page 2-91. bit indicates previous wrong lamp detected.
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Cartridge fan stalled. • Loose connector. Go to “Cartridge fan service check” on page 2-76. • External blockage of the fan, preventing it from turning. • Bad fan. Main fan took too long to •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Mirror moor not up to • Check printhead Go to “Printhead service speed check” on page 2-123. • Check system board No hall effect detected • Check cable connections Go to “Main drive service at motor start.
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Overspeed detected • Faulty motor sensor Go to “Main drive service during speed control. check” on page 2-106. • Faulty system board Motor is type 0. Overspeed detected •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes 949 .0 Delay line calibration System board Replace the system board. See failure “System board and inner shield removal” on page 4-77. NVRAM mismatch Go to “950.00 through 950.29 EPROM mismatch failure”...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Replace the operator panel board or upper front cover. See “Upper front cover removal” on page 4-12 “Upper front cover removal” on page 4-12. Warning: When replacing any one of the following components: •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Replace the interconnect card. “Interconnect card assembly removal” on page 4-54. Warning: When replacing any one of the following components: • Operator panel assembly (or upper front cover) •...
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Service error codes (9xx.xx) (continued) Error Description Possible causes Action code codes Unreliable comma to The engine is experiencing unreliable Service errors 980 thru 984 Paperport device communications to the specified device. <device> can be one of the following: system board, duplex, tray x (1, 2, 3, 4, or 5), Interface protocol The engine protocol violation detected by...
Page 73: User Status Displays

User status displays Warning messages (second lines) These second line warnings apply to the user status displays (see 2-31). For “User status displays” on page example, Ready <warning> 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 to take the printer offline and access the Ready Menu group.
Page 74: User Attendance Messages

User attendance messages User attendance messages Error Primary message Description/action code code Change Cartridge Select one of the following actions: Invalid Refill • Remove the toner cartridge and install a new cartridge. • Press and hold and press to display debug data for the engine and cartridge code.
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User attendance messages (continued) Error Primary message Description/action code code Check Duplex This messages displays for the following conditions: Connection • The duplex option may have been removed from the printer, possibly to clear a paper jam or to remove the option. •...
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User attendance messages (continued) Error Primary message Description/action code code Disk Corrupted The printer has detected there are errors on the hard disk that cannot be Reformat? 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: •...
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User attendance messages (continued) Error Primary message Description/action code code Insert <tray> <tray>=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.
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User attendance messages (continued) Error Primary message Description/action code code Install Env Feed This message is displayed when the envelope feeder has been hot or Cancel Job 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.
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User attendance messages (continued) Error Primary message Description/action code code Reattach Bins x–y=Bins 1 to 5, Bins 2 to 6, or Bins 6 to 10 Bins x–y 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.
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User attendance messages (continued) Error Primary message Description/action code code 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.
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User attendance messages (continued) Error Primary message Description/action code code Insufficient Memory 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.
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User attendance messages (continued) Error Primary message Description/action code code 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. Unformatted Flash This message displays when the printer detects an unformatted flash at power on.
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User attendance messages (continued) Error Primary message Description/action code code Standard Parallel Port This error is displayed when data is sent to the printer across the parallel Disabled 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.
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User attendance messages (continued) Error Primary message Description/action code code Incompatible Tray x An incompatible tray is installed. For Tray x, x= 2, 3, 4, or 5. Remove the incompatible tray and press 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.
Page 85: User Line 2 Link Messages

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.
Page 86: User Attendance Messages-paper Jams And Paper Handling Errors (2xx.xx)

User attendance messages—paper jams and paper handling errors (2xx.xx) When the printer jams, the appropriate jam message will be displayed on the printer operator panel. If you select Show Areas on the operator panel, you can view one or more images to help you clear the jam. 23<x>...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Input sensor covered • Paper pre-staged in path. • Check MPF and friction pad. too quickly • Bouncy input sensor. • Fan media and stack flat in tray or MPF.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Page did not reach exit • Page jammed on fuser input guide. • Check fuser entry guide for sensor. Fuser page toner build up. •...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Page did not reach exit • Page jammed on fuser input guide. • Check fuser entry guide for sensor. Fuser page toner build up. •...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Page did not reach exit • Page jammed on fuser input guide. • Check fuser entry guide for sensor. Fuser page toner build up. •...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Page did not reach exit • Page jammed on fuser input guide. • Check the fuser entry guide sensor. Fuser page for toner build up. •...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Page did not reach exit • Page jammed on fuser input guide. • Check the fuser entry guide sensor. Fuser page for toner build up. •...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Page did not reach exit • Page jammed on fuser input guide. • Check the fuser entry guide sensor. Fuser page for toner build up. •...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Page did not reach exit • Page jammed on fuser input guide. • Check the fuser entry guide sensor. Fuser page for toner build up. •...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Paper jam at fuser exit Page may be jammed in fuser exit or • Make sure the redrive door or redrive area. Fuser redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Exit sensor covered too Page may be jammed in fuser exit or • Make sure the redrive door long. Fuser page count redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Paper jam around fuser Page may be jammed in fuser exit or • Make sure the redrive door or redrive area. Fuser redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Exit sensor covered too Page may be jammed in fuser exit or • Make sure the redrive door long. Fuser page count redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Paper jam around fuser Paper may be jammed in fuser exit or • Make sure the redrive door exit or redrive area. redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Exit sensor covered too Page may be jammed in fuser exit or • Make sure the redrive door long. Fuser page count redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Paper jam around the Page may be jammed in fuser exit or • Make sure the redrive door fuser exit or redrive redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Exit sensor covered too Page may be jammed in fuser exit or • Make sure the redrive door long. Fuser page count redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Paper jam around the Page may be jammed in fuser exit or • Make sure the redrive door fuser exit or redrive redrive. is complete closed. area.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Exit sensor covered too Page may be jammed in fuser exit or • Make sure the redrive door long. Fuser page count redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Paper jam around the Page may be jammed in the fuser exit or • Make sure the redrive door fuser exit or redrive redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Exit sensor covered too Page may be jammed in fuser exit or • Make sure the redrive door long. Fuser page count redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Paper jam around the Page may be jammed in fuser exit or • Make sure the redrive door exit or redrive area. redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Exit sensor covered too Page may be jammed in the fuser exit or • Make sure the redrive door long. Fuser page count redrive area. is complete closed.
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Paper did not clear the • Duplex rear door not fully latched. • Make sure the duplex duplex input sensor but assembly rear door is •...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Paper did not leave the • Duplex jam access tray is not fully • Make sure the duplex jam duplex exit sensor. latched. access tray is installed correctly •...
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User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Duplex exit sensor • Media left in the duplex and Continue • Remove any sheets from covered. selected. the duplex option. • Sensor is having mechanical or •...
Page 112

User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Duplex did not send • Mechanical feed error due to belt Replace the duplex option. device Controls slipping. response. • Timing error due to feed system. Duplex did not send •...
Page 113

User attendance messages—paper jams and paper handling errors (2xx.xx) Error Description Possible causes Action code codes Page was not properly Failure to feed possible causes include: Fan media. picked from tray 1. • Edge locking Turn media over. • Worn or contaminated pick tires Reduce amount of media loaded in tray 1.
Page 114: Service Checks

Service checks Anytime the system board is replaced, the Configuration ID must be reset in NVRAM. Go to “Configuration ID” on page 3-21. Review the following information before performing any service checks. Paper feed problems (especially paper jams): Go to and check the printer •...
Page 115

271.xx Paper Jam—Check Bin 1 displays Action Bottom pass thru sensor Check the flag for correct operation, binding, broken parts, or flag assembly interference from the sensor cable. If incorrect, repair as necessary. If correct, make sure the bottom pass thru sensor is correctly Control board connected to J5 on the control board.
Page 116

Ready—Bin x Full displays and paper feeds into bin x Action Bin x sensor Check the sensor flag for binds. Make sure the sensor flag is not in Bin x sensor control board an up position. If the sensor flag is operating correctly, replace the bin x sensor.
Page 117: 900.xx Error Code Service Check

Sub Error Codes on the display. Check the “Base 2-9. If none of the Sub Error printer sub error codes” on page Codes are listed, then call your next level of support or call Dell. Diagnostic information 2-75...
Page 118: 927.xx Fan Service Check

927.xx Fan service check 927.xx can be used for the main fan or the cartridge fan. Main fan—927.00, 927.01, and 927.03 through 927.07. • Cartridge fan—927.02 • Main fan Service tip: The main fan runs at full speed at the end of POR or when the printer is printing. It will only run half speed when the printer is in the Ready state and not printing.
Page 119: 950.00 Through 950.29 Eprom Mismatch Failure

950.00 through 950.29 EPROM mismatch failure When replacing any one of the following components: Warning: Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly • Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.
Page 120: 950.30 Through 950.60 Eprom Mismatch Failure

950.30 through 950.60 EPROM mismatch failure When replacing any one of the following components: Warning: Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly • Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.
Page 121: Charge Roll Service Check

Action System board Replace the current system board with the original system board. “System board and inner shield removal” on page 4-77. If the error remains, go to step 6. Interconnect card assembly Replace the original interconnect card assembly with a new and not previously installed interconnect card assembly.
Page 122: Cover Closed Switch/cable Service Check

Cover closed switch/cable service check Action 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.
Page 123

Action +5 V dc test point on the Check for approximately +5 V dc at the +5 V test point on the system system board board. Note: Use care not to short adjacent voltage test points. If the voltage is correct, replace the system board assembly. If the voltage is incorrect, go to step 4.
Page 124: Duplex Option Service Check

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.
Page 125

231.xx Jam displays on the operator panel Action 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.
Page 126: Envelope Feeder Service Check

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.
Page 127

260.xx Paper Jam Operator panel displays after attempted feed but before envelopes are Load Envelopes put in the hopper OR the operator panel continues to display after envelopes are placed in the hopper Service tip: The kick rolls rotate during the attempted feed cycles. Action Envelope out hopper Check the envelope out sensor flag for damage, correct installation...
Page 128

260.xx Paper Jam displays, envelope stops in feeder paper path Action Kick rolls/feed rolls/drive Check all the rolls for oil, grease, or other contamination. If you find a rolls problem, clean the rolls. If this does not correct the problem, replace the envelope feeder.
Page 129: Fuser Service Checks

Fuser service checks 920.xx—Cold fuser service check Error codes 920.x and 922.xx may display for a cold fuser failure. Some 920.xx error codes may be cleared by turning the printer on and off and allowing it to complete POR. CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working.
Page 130

Action LVPS CAUTION: When taking measurements for AC power, observe all safety precautions. LVPS to fuser AC cable Check the AC line voltage between the pins on the fuser end of the LPVS to fuser AC cable. If the voltage is correct, unplug the AC power cord from the LVPS cable.
Page 131: 922.xx-cold Fuser Check

922.xx—Cold fuser check Error codes 920.xx and 922.xx may display for a cold fuser failure. Some 920.xx error codes may be cleared by turning the printer on and off and allowing it to complete POR. CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working.
Page 132: 923.xx-hot Fuser Service Check

Action Fuser assembly If no problem is found up to this point, then replace the following in the order shown: • Fuser assembly. See “Fuser assembly removal” on page 4-27. • System board assembly. See “System board and inner shield removal”...
Page 133: 925.xx-hot Fuser Service Check

924.xx—Hot fuser service check Error Code 923.xx, 924.xx, and 925.xx may display for a hot fuser failure. 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.
Page 134: Fuser Exit Sensor Service Check

Action Fuser lamp Turn the printer off and allow the fuser assembly to cool. After the fuser assembly cools down, turn the printer on. If you receive the same error code, replace the fuser lamp. See “Fuser lamp removal” on page 4-33.
Page 135: Fuser Narrow Media Sensor Service Check

Action With the redrive assembly removed from the printer, enter the Diagnostics mode and run the print test from tray 1 (for example, select PRINT TESTS, Tray 1, and Continuous) and observe the media as it passes over the exit and narrow media sensors. Check that the sensor flags are operating correctly.
Page 136

Action With the redrive assembly removed from the printer, enter Diagnostics mode and run the printer test from tray 1 and observe the media as it passes over the exit sensor. Check to see that the sensor flag is operating correctly. If the sensor flag and hardware are operating incorrectly, repair or replace the failing sensor assembly.
Page 137: Fuser Solenoid Service Check

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.
Page 138: High-capacity Feeder Input Tray Service Check

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.
Page 139

Action High-capacity feeder option Check the voltage on J8-1 (green). The voltage measures +24 V dc. control board 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.
Page 140

Tray x Empty displays when there is paper in the high-capacity feeder input tray Action Paper out sensor flag 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.) Paper out sensor (on option system board)
Page 141

The elevator tray does not move up or down; the printer recognizes that the option is installed Action DC drive motor high- Be sure the motor cable is correctly installed at J1 on the board. capacity feeder option Check the cables, damaged or loose wires. Disconnect the motor. system board Check for a short between each pin and the motor housing.
Page 142

Paper size switch not selecting paper size that is selected Action Paper size switch Check for continuity between the common pin (J5-1) and the pin of High-capacity feeder option the paper size selected. control board Color Paper size J5-1 Black Common lead J5-2 Blue...
Page 143: High-capacity Output Stacker Service Check

Tray x Paper Low displays when the high-capacity feeder input tray is full or has adequate paper in the tray Action Paper low switch Run the sensor diagnostics for tray x (x=the number that represents the high-capacity input tray). Paper low switch cable High-capacity feeder option If the test fails, check the voltage at J3-1 (gray).
Page 144

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.
Page 145: Input Sensor Service Check

Paper Jam - Check Bin x 271.xx , POST incomplete Action Upper pass thru sensor flag Check the flag for correct operation, binding, broken parts, or assembly interference from the sensor cable. If incorrect, repair as necessary. If correct, make sure the lower pass thru sensor is correctly Upper control board connected to J3 on the lower control board.
Page 146

24x.xx 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) Action Pass thru sensor and flag The tray x option system board did not detect a piece of paper assembly actuating the pass thru sensor.
Page 147: Interconnect Card Service Check

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. Action Autocompensator Check the autocompensator pick arm rollers for any sign of glazing,...
Page 148: Main Drive Service Check

Main drive service check Service tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or system board. Whenever the gearbox assembly is removed from the machine it must be handled very carefully. Warning: Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage.
Page 149: Operator Panel Service Check

Operator panel service check Note: The operator panel board is a separate FRU and is also part of the upper front cover FRU When replacing any one of the following components: Warning: Operator panel assembly (or upper front cover) • System board assembly •...
Page 150: Operator Panel Display

Operator panel display Service tip: The printer has detected a problem with the system board, the operator panel cable (part of the upper front cover hinge assembly), or the operator panel board if POST does not complete, the printer emits 5 beeps, and stops in a continuous pattern until the printer is turned off.
Page 151: Options Service Check

Options service check Service tip: When you have a problem with any of the options installed in the options slots on the interconnect card, 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.
Page 152: Output Bin Sensor Standard Tray Service Check

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: Enter the Diagnostics Mode. Select Output Bin Tests. Select Sensor Tests. Select Standard Bin.
Page 153: Output Expander Service Check

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.
Page 154

Remove Paper—Output Bin x displays, POST incomplete, unable to clear the message 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. or replace the output expander option. 271.xx Paper Jam—Check Bin x , POST incomplete Action...
Page 155: Paper Feed Service Check

Paper feed service check If you have a 936 Transport Motor Error go to “Main drive service check” on page 2-106. Action 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.
Page 156: Paper Size Sensing Service Check

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.
Page 157

Tray 1 Missing Tray 1 not recognized as being installed; unable to clear message 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. If a problem is found, repair or replace the tray assembly.
Page 158

The printer does not recognize the paper size selected Action Back restraint Check all the paper size parts for damage or broken parts. make sure Side restraint the parts operate correctly. If a problem is found, repair as Snap-in plate necessary.
Page 159: Parallel Port Service Check

Parallel port service check Run the “Parallel Wrap tests” on page 3-8. 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.
Page 160

Action HVPS cable Check the continuity of the HVPS cable. If incorrect, replace the (part of front cable assembly. If correct, replace the system board. harness cable) System board Print quality—blank page Action Print cartridge Check the print cartridge for damage, especially the PC drum contact on the cartridge.
Page 161

Check the high voltage contacts to ensure they are not bent, corroded, or damaged. Replace as necessary. Print quality—background Service tip: Some background problems can be caused by rough papers, non-Dell toner cartridges or if the media texture is set to the rough setting.
Page 162

Action System board HVPS Check the following voltages at J15 on the system board. Measure connector the voltages from J15 to printer ground. Pin J15 Voltage (approximate) Printer idle J15-1 0 V dc J15-2 +4 V dc J15-4 0 V dc Printer printing J15-1 0 V dc t o + 5 V dc...
Page 163

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. Action Charge roll counterbalance If the problem is just on one side of the page, check the charge roll springs counterbalance spring on that side.
Page 164

Print quality—light print Service tip: Check the toner saver and print darkness settings first if the print is light. Action Transfer roll Check the right end of the transfer roll shaft for signs of wear or contamination. If incorrect, replace the transfer roll. Right side transfer roll arm Check the right side transfer roll arm assembly bearing for wear or assembly...
Page 165: Printhead Service Check

Signature button assembly service check Note: If you are unable to clear a 32.xx-Unsupported Cartridge User Error message, be sure a Dell 5210n/ 5310n 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.
Page 166: Staplesmart Finisher Service Check

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 Action Top cover...
Page 167

POST incomplete—stapler cycles several times 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. 990.xx Service Error Code—Check Bin x displayed—POST incomplete •...
Page 168

Insert Stapler Cartridge POST incomplete— 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.xx Stapler Jam displayed.
Page 169: System Board Service Check

Paper feeds into finisher option output tray—Paper is not stapled—Paper does not align with the right side Replace the stapler option. Misalignment of sheets to be stapled Action Left side bail assembly Check the left side bail assembly for any signs of binding, missing, or broken parts.
Page 170: Toner Sensor Service Check

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.xx Service Error displays. Action Developer drive assembly Incorrect operation of the developer drive assembly can cause the printer to display a 929.xx error code (Toner Sensor).
Page 171: Transfer Roll Service Check

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.
Page 172

Service Manual 2-130...
Page 173: Diagnostic Aids

3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics Mode 1.
Page 174: Entering Diagnostics Mode

Diagnostics mode Entering Diagnostics mode Press and hold Turn on the printer. Release the buttons when Performing Self Test displays. Available tests The tests display on the operator panel in the order shown: Diagnostics mode tests REGISTRATION “REGISTRATION” on page 3-4 Bottom Margin Top Margin Left Margin...
Page 175

Diagnostics mode tests (continued) DUPLEX TESTS (if installed) Quick Test “Quick Test (duplex)” on page 3-9 Top Margin “Top Margin (duplex)” on page 3-10 Sensor Test “Sensor Test (duplex)” on page 3-10 Motor Test “Motor Test (duplex)” on page 3-11 Duplex Feed 1 “Duplex Feed 1”...
Page 176: Exiting Diagnostics Mode

Diagnostics mode tests (continued) EP SETUP EP Defaults “EP Defaults” on page 3-22 Fuser Temp “Fuser Temperature (Fuser Temp)” on page 3-22 Fuser Page Count “Fuser Page Count” on page 3-22 Warm Up Time “Warm Up Time” on page 3-22 Transfer “Transfer”...
Page 177: Quick Test

to select the margin setting you need to change, and press The Top margin sign/value pair blinks. This indicates it is the margin value being changed. T=xxx* B=xxx* L=xxx* R=xxx* to decrease or to increase the offset values, and press to confirm the value.
Page 178: Print Tests

PRINT TESTS Input source 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. The contents of the Print Test Page varies depending on the media installed in the selected input source.
Page 179: Hardware Tests

HARDWARE TESTS Select the following Hardware Tests from this menu: Panel Test • Button Test • DRAM Test • ROM Memory Test • Parallel Wrap (if available) • Serial Wrap (if available) • Panel Test This test automatically toggles each pixel of the operator panel through every contrast level beginning with the darkest and on to the brightest.
Page 180: Cache Test

CACHE Test This test is used to verify the printer processor cache. To run the CACHE Test: Select CACHE TEST from HARDWARE TESTS. The message CACHE Test Testing… displays. Then the message Resetting Printer appears. The printer automatically performs a Power On Reset (POR). While the CACHE test executes, the power indicator blinks green.
Page 181: Serial Wrap Tests

Serial Wrap tests The serial wrap tests are used to check the operation of the serial port hardware using a wrap plug. Use Serial 1 Wrap if a serial port is available through PCI slot 1 and Serial 2 Wrap if the serial port is available through PCI slot 2.
Page 182: Top Margin (duplex)

Top Margin (duplex) This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin.
Page 183: Motor Test (duplex)

Motor Test (duplex) This test lets you test the duplex option paper feed drive system, and verify that the power and velocity values are acceptable. The duplex runs the DC motor at high speed and low speed, taking an average of the power (PWM) required for each speed and calculating the KE value.
Page 184: Duplex Feed 1

Duplex Feed 1 This test feeds a blank sheet of paper to the duplex paper stop position 1. This test can be run using any of the supported paper sizes. To run the Duplex Feed 1 Test: Select Duplex Feed 1 from DUPLEX TESTS. The power indicator blinks while the paper is feeding, and the message Duplex Feed 1 Feeding…...
Page 185: Input Tray Tests

INPUT TRAY TESTS Feed Tests (input tray) 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.
Page 186: Output Bin Tests

OUTPUT BIN TESTS Feed Tests (output bins) Use these tests to verify that media can be fed to a specific output bin. Media is fed from the default input source to the selected output bin. No information is printed on the media fed to the output bin because the printhead is not engaged during this test.
Page 187: Sensor Test (standard Output Bin)

Sensor Test (standard output bin) This test is used to verify if the standard bin sensor is working correctly. To run the Sensor Test for the standard bin: Select Sensor Test from OUTPUT BIN TESTS. Select Standard Bin from Sensor Tests. Select NearFull or Full sensor to test.
Page 188: Sensor Test (high Capacity Output Stacker)

Sensor Test (high capacity output stacker) Select Sensor Test from OUTPUT BIN TESTS. Select Output Bin x (x=number of the output option to be tested). The following screen is displayed: HC Bin x TP=OPpassThru=Open Full=Open NearFull=Open TP—High-capacity top position sensor •...
Page 189: Finisher Tests

FINISHER TESTS Staple Test This test verifies the staple mechanism by sending eight sheets of media from the printers default paper source and stapling the sheets. To run the Staple Test: Select Staple Test from FINISHER TESTS. Select the output bin and press While the test runs the power indicator blinks and the message Staple Test Running…...
Page 190: Base Sensor Test

BASE SENSOR TEST This test is used to determine if the sensors located inside the printer are working correctly. To run the Base Sensor Test: Select BASE SENSOR TEST from the DIAGNOSTICS menu. The following sensors are listed: Exit—Exit sensor •...
Page 191: Disk Test/clean

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 1½ hours depending on the disk size. To run the Disk Test/Clean Test: Select Disk Test/Clean from the Device Tests menu.
Page 192: Printer Setup

PRINTER SETUP Defaults US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US factory defaults. The settings affected include paper size, envelope size, PCL symbol set, code pages, and units of measure. Warning: Changing this setting resets the printer to factory defaults, and data may be lost. It cannot be undone. Page Count The page count can only be viewed and cannot be changed.
Page 193: Configuration Id

Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The configuration IDs are originally set at the factory when the printer is manufactured, however the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever you replace the system board.
Page 194: Ep Setup

EP SETUP EP Defaults This setting is used to restore each printer setting listed in EP SETUP to its factory default value. Sometimes this is used to help correct print quality problems. To restore EP Defaults: Select EP Defaults from EP SETUP. Select Restore to reset the values to the factory settings, and select Do Not Restore to exit without changing the settings.
Page 195: Event Log

Time and date stamps • Page counts for most errors • Additional debug information in some cases • The printed event log can be faxed to Dell or your next level of support for verification or diagnosis. Diagnostic aids 3-23...
Page 196: Clear Log

To print the event log: Select Print Log from EVENT LOG. Press Back ( to return to EVENT LOG. Clear Log Use Clear Log to remove the current information in the Event Log. This affects both the viewed log and the printed log information.
Page 197: Configuration Menu (config Menu)

Configuration menu (CONFIG MENU) Entering Configuration Menu Turn off the printer. Press and hold Turn on the printer. Release the buttons when Performing Self Test displays. The message CONFIG MENU displays on the top line of the operator panel. Available menus Maint Cnt Value “Maintenance page count (Maint Cnt Value)”...
Page 198: Maintenance Page Counter Reset (reset Maint Cnt)

To view the maintenance page count: Select Maint Cnt Value from CONFIG MENU. Press to view the value. Press Back ( ) to return to the main Configuration menu. Maintenance page counter reset (Reset Maint Cnt) After scheduled maintenance, the servicer needs to reset the page counter. To reset the maintenance page count to zero: Select Reset Maintenance Count from the Configuration menu.
Page 199: Size Sensing

SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing. Paper source Size sensing Tray 1 (integrated) Multipurpose feeder 250-sheet drawer 500-sheet drawer 2000-sheet drawer 250-sheet duplex 500-sheet duplex Envelope feeder When the setting is Auto, every input option equipped with size sensing hardware automatically registers what size media it contains.
Page 200: Factory Defaults

Factory Defaults This setting enables a user to restore all the printer settings to the original factory settings. Selections are Restore Base and Restore Network. Network does not appear unless you have a network printer. The following settings are not changed: Display language •...
Page 201: Font Sharpening

Font Sharpening This setting allows a user to set a text point size below which the high frequency screens are used when printing font data. For example, at the default 24, all text in font sizes 24 and less will use the high frequency screens. The values for this setting range from 0 to 150, and the default value is 24.
Page 202: Menu Settings Page

Menu settings page You can print a menu settings page to review the default printer settings and to verify your printer options are installed correctly. Press Menu ( to display Menus. Press until the appears next to Reports. Press . Press until the appears next to Menu Settings Page.
Page 203: Theory

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.
Page 204: Autoconnect System, Paper Tray Options, Envelope Feeder-electrical

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.
Page 205: Print Quality Troubleshooting

Print quality troubleshooting To help isolate print quality problems, print the “Print defects guide” and check for repeating defects. If repeating defects are not appearing, print the Print Quality Test Pages. Turn the printer off. Hold down , and turn the printer on. Press until Prt Quality Pgs is selected, and then press The pages are formatted.
Page 206

Problem Action Toner fog or background shading • Check the print cartridge to make sure it is installed correctly. appears on the page. • The Toner Darkness setting may be too dark. Change the Toner Darkness setting in the Quality Menu. •...
Page 207

Problem Action Characters have jagged or uneven • Change the Print Resolution setting in the Quality menu to 600 edges. dpi, 1200 Image Q, 1200 dpi, or 2400 Image Q. • Enable Enhance Fine Lines. See the tables on page “Quality menu operator panel options”...
Page 208

The quality menu operator panel options can be adjusted to help improve print quality. Quality menu operator panel options Menu selection Purpose Values Print Resolution To select printed output resolution 600 dpi (default setting) 1200 Image Q 1200 dpi 2400 Image Q Toner Darkness Lightens or darkens printed output 1–10...
Page 209: Paper Feed Jams

2000-sheet drawer. Certain other configurations also must have a printer stand or printer base. More information is available at the Dell Web site at www.dell.com. Clearing printer jams Although there are several places a jam can occur, clearing the paper path is fairly easy depending on the jam message or messages displayed on the operator panel.
Page 210: 250 Paper Jam Check Mp Feeder

250 Paper Jam Check MP Feeder Remove the paper from the multipurpose feeder. Flex, fan, and restack the media, and place it into the multipurpose feeder. Load the print media. Slide the side guide toward the inside of the tray until it lightly rests against the edge of the media. Press .
Page 211: 260 Paper Jam Check Env Feeder

260 Paper Jam Check Env Feeder The envelope feeder feeds envelopes from the bottom of the stack; the bottom envelope will be the one that is jammed. Lift the envelope weight. Remove all envelopes. If the jammed envelope has entered the printer and cannot be pulled out, remove the envelope feeder. Lift the envelope feeder up out of the printer, and then set it aside.
Page 212: 23x And 24x Jams

23x and 24x jams Paper jams in these areas can occur on the incline surface of a tray or across more than one tray. To clear these areas: Open the printer paper tray, and remove any jammed media. Open the duplex tray. To remove the media, pull up.
Page 213: 200 And 201 Paper Jam Remove Cartridge

If you have an optional 2000-sheet feeder, open the front door, press the elevator button (A) to lower the tray, remove the jam, and make sure the stack of print media is neat and aligned. Press . 200 and 201 Paper Jam Remove Cartridge Push the release latch, and lower the multipurpose feeder.
Page 214

Place the print cartridge aside. Note: Do not leave the cartridge exposed to light for extended periods. Note: The print media may be covered with unfused toner, which can stain garments and skin. Pull the print media up and toward you. Warning: If the print media does not move immediately when you pull, stop pulling.
Page 215: 202 Paper Jam Open Rear Door

202 Paper Jam Open Rear Door If the paper is exiting the printer, pull the media straight out, and press . Otherwise continue with step 2. Open the printer rear door. Remove the jammed media. Close the rear door. Press . Diagnostic aids 3-43...
Page 216: 23x Paper Jam Open Duplex Rear Door

23x Paper Jam Open Duplex Rear Door Open the duplex rear door. Remove the jammed media. Depending on the media location, pull the media either up or down. Close the duplex rear door. Make sure it snaps into place. Press . Service Manual 3-44...
Page 217: 270 And 280 Paper Jams

270 and 280 Paper Jams Paper jams in this group have been divided into 27x and 28x groups. If you have an output expander, high- capacity output stacker, or the 5-bin mailbox, see x”. If you have a finisher, see “27x Paper Jam Check Bin “28x Paper Jam Check Finisher”.
Page 218: 28x Paper Jam Check Finisher

Remove the jammed media. Close the output bin rear doors, and make sure all doors are secure. Press . 28x Paper Jam Check Finisher To clear a jam in the finisher: Push the finisher rear door latches in toward the center. The rear door will open and drop down. Remove the jammed media.
Page 219

Lift the front edge of the finisher output bin cover until it locks into position. Remove the stack of print media. Close the finisher output bin cover. Press . Diagnostic aids 3-47...
Page 220: Clearing Staple Jams

Clearing staple jams A 28x Stapler Jam message indicates staples are jammed in the stapler. This requires removing the staple cartridge holder from the printer. Lift the front edge of the finisher output bin cover until it locks into position. Remove the print media.
Page 221

Press down on the staple guard until it snaps securely into place. Push the cartridge holder firmly into the stapler until the cartridge holder clicks into place. Close the stapler access door. Close the finisher output bin cover. Diagnostic aids 3-49...
Page 222

Service Manual 3-50...
Page 223: Repair Information

4. Repair information Read the following before handling electronic parts. Warning: 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 •...
Page 224: Adjustment Procedures

Adjustment procedures 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.
Page 225: Paper Alignment Assembly Adjustment

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.
Page 226

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 3-4. The reference screw can be adjusted “REGISTRATION” on page 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.
Page 227: Removal Procedures

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. CAUTION: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.
Page 228: Redrive Cap Cover Removal

Redrive cap cover removal Pull up on the right side of the redrive cap cover to remove. Remove the redrive cap cover. Paper support removal Raise the paper support, and lift to release the latches. Remove the paper support. Service Manual...
Page 229: Left Door Removal

Left door removal Open the upper and lower front covers. Press the two left door latch buttons (A), and open the left door. Release the top hinge from the latch. Repair information...
Page 230: Redrive Door

Lift the door to release the bottom from the pin (B), and remove the door. Redrive door With the redrive door partially open, lift and free the left side. Remove the redrive door. Service Manual...
Page 231: Right Cover Removal

Right cover removal Remove the redrive cap. See“Redrive cap cover removal” on page 4-6. Open the upper and lower front covers. Remove the print cartridge. Remove the right front cover mounting screw (A). Remove the redrive door. See “Redrive door” on page 4-8.
Page 232

Remove the right rear cover mounting screw (C). Press the two latches to remove the redrive assembly. Service Manual 4-10...
Page 233

Press the latch (D) firmly to release the front of the right cover. Pull up and out on the right cover to release the three cover retainers (E) at the bottom. Note: When replacing the right side cover, make sure the three cover retainers are correctly located in the appropriate slots in the right side frame.
Page 234: Upper Front Cover Removal

Upper front cover removal When replacing any one of the following components: Warning: Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly • Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.
Page 235

Disconnect the cables. Note: It may be necessary to remove the operator panel cable from the cable clip (C) to be able to disconnect the cable from the operator panel. Remove the upper front cover. Note: If you are replacing the upper front cover, remove the upper front cover outer bezel and upper front cover latch.
Page 236: Upper Front Cover Latch Removal

Upper front cover latch removal Remove the upper front cover. Remove the screw (A) holding the latch and spring to the upper front cover. Installation note: The spring (B) is installed as shown. Service Manual 4-14...
Page 237: Upper Front Cover Outer Bezel Removal

Upper front cover outer bezel removal Open the lower front cover. Open the upper front cover. Remove the two small upper front cover outer bezel mounting screws (A). Pull up to remove the outer bezel. Note: If available, place a soft, clean cloth on the open lower front cover. The clear inner bezel (B) is not connected and may fall.
Page 238: Multipurpose Feeder/lower Front Cover Assembly Removal

Multipurpose feeder/lower front cover assembly removal Open the multipurpose tray to a position that allows the left and right tray hinge slots (A) to align with the D-shape mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts.
Page 239: Left Cover Handle Holder Removal

Left cover handle holder removal Open the left side cover. Remove the outer system board shield. See “Outer shield removal” on page 4-69. Remove the two screws (A) holding the top of the left handle holder in place. Use the tab (B) to lift out the left handle holder. Right cover handle holder removal Remove the right side cover.
Page 240: Left And Right Frame Extensions

Left and right frame extensions Remove the toner cartridge. Turn the printer on its back. Remove the two screws (A) holding the right frame extension. Remove the two screws (B) securing the left frame extension. Service Manual 4-18...
Page 241: Pass Thru Plate

Pass thru plate Remove the redrive assembly. See “Redrive assembly removal” on page 4-75. Remove the screw (A) securing the pass thru plate. Carefully remove the plate until it is loose. Remove the fuser to system board DC cable (B) secured through the plate. Note: Note the routing of the fuser card to system board DC cable.
Page 242: Laser Cover Removal

Laser cover removal Remove the left door. See “Left door removal” on page 4-7. Remove the right cover. See “Right cover removal” on page 4-9. Remove the paper support. See “Paper support removal” on page 4-6. Remove the redrive cap. See “Redrive cap cover removal”...
Page 243

Remove the paper bin full sensor flag from the mounting bracket. See “Paper bin full sensor flag removal” on page 4-71. Unlatch the front right and front left cover posts, and remove the cover. Repair information 4-21...
Page 244: Bevel Gear Removal

Bevel gear removal 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. 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.
Page 245

Installation Remove any washer that may be present (A) and discard. Lubricate areas (A) that engage the journal (B) with grease from the provided packet. Place the new washer (C) on the bevel gear shaft. Insert the bottom portion and press or pull into position. Note: You should hear two distinct snaps.
Page 246: Cartridge Duct Removal

Cartridge duct removal Open the left door. Disconnect the printhead laser cable from J2 on the system board. Remove the three screws securing the cartridge duct (A). Note: It may be necessary to pull the main fan cable (B) up and out of the way to remove the duct. Reconnect the printhead laser cable.
Page 247: Developer Drive Assembly Removal

Developer drive assembly removal Remove the system board and inner shield. See “System board and inner shield removal” on page 4-77. Remove the two short screws (A) and the one long screw (B) securing the developer drive assembly. Remove the developer drive assembly. Remove the developer drive coupler kit.
Page 248: Developer Drive Coupler Kit Removal

Developer drive coupler kit removal Remove the developer drive. See “Developer drive assembly removal” on page 4-25. Remove the shaft drive and coupler. ESD cover removal Open the multipurpose tray, and remove the tray from the two mounting posts. See “Multipurpose feeder/lower front cover assembly removal”...
Page 249: Fuser Assembly Removal

Fuser assembly removal CAUTION: Unplug the printer before you begin. Remove the fuser wick assembly cover. See “Fuser wiper cover assembly removal” on page 4-5. Remove the redrive assembly. See “Redrive assembly removal” on page 4-75. Remove the fuser mounting screws (A). Disconnect the fuser to LVPS AC cable (B) from the fuser lamp connector (C).
Page 250: Installation Notes

Disconnect the fuser to system board DC cable (D) from the fuser board. Note: Be sure to observe the routing of the LVPS to fuser lamp AC and the DC cable. Pull the cables free and remove the fuser. Installation notes When you reinstall the fuser, be sure to route the fuser to LVPS AC cable (A) through the channel (B) on the right side frame above the LVPS, under the clip (C) over the LVPS, and through the notch in the frame (D).
Page 251: Fuser Exit Sensor Removal

Connect the fuser to LVPS AC cable to the fuser lamp connector (F) at the LVPS. Note: Be sure to connect the fuser to system board DC cable after replacing the LVPS. Fuser exit sensor removal Remove the fuser. See “Fuser assembly removal”...
Page 252

Installation Move the fuser exit sensor flag out of the way to clip the sensor securely into the cover. Connect the fuser exit sensor cable. Snap the bottom fastener of the sensor cover into place in the lower exit guide, and use a small flat bladed screwdriver to ease the sensor cover into the clips.
Page 253: Fuser Exit Sensor Flag And Spring Removal

Fuser exit sensor flag and spring removal Remove the fuser exit sensor. See “Fuser exit sensor removal” on page 4-29. Note the position of the spring (A) in relation to the flag (B). Carefully ease the right arm (C) until the fuser exit sensor cover releases the flag and spring. Spring replacement Place the spring on the left pin (A).
Page 254

Rotate the bent end (C) of the spring to add tension, place the pins between the sensor cover arms, and rest the bent end against the sensor cover frame. Note: After replacing the sensor, flag, and spring, make sure the flag moves freely and returns. Service Manual 4-32...
Page 255: Fuser Lamp Removal

Fuser lamp removal CAUTION: The fuser and the fuser lamp may be hot. You may need to allow them to cool before handling them. Remove the fuser assembly. See “Fuser assembly removal” on page 4-27. Disconnect the fuser lamp AC cable from the right side of the top cover assembly. Remove the two screws (A) from the right side fuser lamp contact cover.
Page 256

Remove the fuser lamp. The lamp is under spring tension, and care must be used when removing the lamp from the Warning: 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.
Page 257: Fuser Narrow Media Sensor Removal

Fuser narrow media sensor removal Remove the redrive assembly. See “Redrive assembly removal” on page 4-75. Remove the screw (A) securing the narrow media sensor cover to the fuser. With a thumbnail, release the catches (B) holding the sensor cover to the lower exit guide (C) in place. Note: You may need to move the narrow media flag out of the way to remove the sensor.
Page 258

Replacement Move the narrow media flag out of the way to clip the sensor securely into the cover. Connect the fuser narrow media cable. Snap the bottom fastener of the sensor cover into place in the lower exit guide, and rock the cover up until the top fastener snaps securely.
Page 259: Fuser Narrow Media Flag And Spring Removal

Fuser narrow media flag and spring removal Remove the fuser narrow media sensor. See “Fuser narrow media sensor removal” on page 4-35. Note the position of the spring (A) in relation to the flag (B). Carefully ease the right arm (C) of the sensor cover just far enough apart to release the flag and spring. Spring replacement Place the spring on the left pin (A).
Page 260

Rotate the bent end (C) of the spring to add tension, place the pins between the sensor cover arms, and rest the bent end against the sensor cover frame. Note: After replacing the sensor, flag, and spring, make sure the flag moves properly. Service Manual 4-38...
Page 261: Fuser To Lvps Ac Cable Removal

Fuser to LVPS AC cable removal CAUTION: Unplug the printer before you begin. Remove the fuser wick assembly cover. See “Fuser wiper cover assembly removal” on page 4-5. Remove the redrive assembly. See “Redrive assembly removal” on page 4-75. Remove the right side cover. See “Right cover removal”...
Page 262

Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS AC cable from the LVPS (E). Note: The LVPS assembly may be difficult to remove from the printer. Do not use excessive force in the removal.
Page 263

Route the cable through the lower rectangular opening (E). Connect the fuser to LVPS AC cable to the fuser lamp connector (F). Note: Be sure to connect the fuser to system board DC cable after replacing the LVPS. Repair information 4-41...
Page 264: Fuser Top Cover Removal

Fuser top cover removal CAUTION: Unplug the printer before you begin. Remove the fuser assembly. See “Fuser assembly removal” on page 4-27. Note the thermistor cable routing (A) and disconnect the thermistor cable at the fuser control board. Disconnect the AC fuser lamp cable (B) from the top right side of the fuser cover. Service Manual 4-42...
Page 265

Carefully remove the two screws (C) from the right side of the fuser lamp contact cover (D). Release the latch (E) and remove the cover. Remove the screw (F) on the left side and the screw (G) on the right side that attach the fuser upper cover assembly to the fuser frame.
Page 266: Fuser Transfer Plate Removal

Remove the fuser cover. Fuser transfer plate removal Remove the upper paper deflector. See “Upper paper deflector assembly removal” on page 4-80. Remove the transfer roll. See “Transfer roll assembly removal” on page 4-78. Remove the inner paper deflector. See “Inner paper deflector assembly removal”...
Page 267: Gear Release Link Removal

Gear release link removal Remove the system board and inner shield. See “System board and inner shield removal” on page 4-77. Remove the developer drive. Disconnect the gear release link (A) from the hole in charge roll link (B). Note: Lift the upper front cover to make it easier to remove the link. Rotate the link to disconnect the link from the main drive assembly.
Page 268: High Voltage Power Supply Removal

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. Remove the inner paper deflector.
Page 269

Remove the HVPS mounting screws (C). Slide the HVPS to the left to release the mounting tab from the center pan, and remove the HVPS. Repair information 4-47...
Page 270: Inner Paper Deflector Assembly Removal

Inner paper deflector assembly removal Remove the paper tray. Remove the upper paper deflector assembly. See “Upper paper deflector assembly removal” on page 4-80. Remove the MPF lower deflector assembly. See “MPF lower paper deflector” on page 4-62. Place the printer on its side. 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.
Page 271: Input Sensor Removal

Input sensor removal Remove the upper paper deflector. “Upper paper deflector assembly removal” on page 4-80. Loosen the MPF lower front cover. See “Multipurpose feeder/lower front cover assembly removal” on page 4-16. Remove the inner paper deflector.“Inner paper deflector assembly removal” on page 4-48.
Page 272: Integrated Tray Autocompensator Assembly Removal

Integrated tray autocompensator assembly removal Remove the paper tray. Remove the left door. See “Left door removal” on page 4-7. Remove the outer shield. See “Outer shield removal” on page 4-69. Place the printer on its back. Disconnect the autocompensator motor cable (A) from the system board (J24). Service Manual 4-50...
Page 273

Locate the integrated tray autocompensator assembly (B) on the bottom of the printer, and disconnect the autocompensator arm bias spring (C). Note: When you remove the spring, note the larger loop attaches to the side frame. Remove the C-clip (D) that rests against the right side frame from the autocompensator pivot shaft. Disconnect the autocompensator sensor cable (E) from the assembly.
Page 274: Integrated Tray Autocompensator Pick Roll Assembly Removal

Integrated tray autocompensator pick roll assembly removal Remove the integrated tray, and look underneath the printer for the autocompensator arm. Pull the arm down. Press on the end of the tab (A) and pull the pick roll off the arm. Repeat this step for the pick roll on the other side.
Page 275

Installation Remove the new pick rolls from their packaging. 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.
Page 276: Interconnect Card Assembly Removal

Interconnect card assembly removal CAUTION: Unplug the printer before you begin. When replacing any one of the following components: Warning: Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly • Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.
Page 277: Low Voltage Power Supply Removal

Low voltage power supply removal CAUTION: Unplug the printer before you begin. Remove the redrive assembly. See “Redrive assembly removal” on page 4-75. Remove the right side cover. See “Right cover removal” on page 4-9. Remove the pass thru plate. See “Pass thru plate”...
Page 278

Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser to LVPS AC lamp cable (D). The LVPS assembly may be difficult to remove from the printer. Do not use excessive force in Warning: the removal.
Page 279: Main Fan Removal

Main fan removal Open the left side cover. Remove the outer shield. See “Outer shield removal” on page 4-69. Remove the two screws (A) securing the main fan cap. Remove the main fan cap. Clip the cable tie (B). Note: Be careful not to damage any of the cables. Note the location of the cable tie for later replacement. Disconnect the main fan to the system board (C) at J4.
Page 280: Main Drive Assembly Removal

Installation note: The fan has an orientation marking (D). Be sure to install the fan with the arrow pointing up. Main drive assembly removal Remove the system board and inner shield. See “System board and inner shield removal” on page 4-77.
Page 281

Lift and remove the cables from the cable hooks (B). Remove the ground cable screw (C). Remove the main drive assembly mounting screws (D). Repair information 4-59...
Page 282

Disconnect the gear release link (E) from the hole in the charge roll link (F). Note: Lift the upper front cover to make it easier to remove the link. Disconnect the main drive motor cable from the main drive assembly. Remove the main drive assembly.
Page 283: Mpf Arm Assembly Removal

MPF arm assembly removal Open the left door. Remove the MPF lower front cover. See “Multipurpose feeder/lower front cover assembly removal” on page 4-16. Remove the MPF lower paper deflector. See “MPF lower paper deflector” on page 4-62. Remove the upper paper deflector. See “Upper paper deflector assembly removal”...
Page 284: Mpf Lower Paper Deflector

Installation note: Note the order of C-clips bushing, and washer when you reinstall. MPF lower paper deflector Remove the MPF lower cover. Remove the four screws securing the MPF lower paper deflector. Remove the defector. Service Manual 4-62...
Page 285: Mpf Pick Tire Removal

MPF pick tire removal Remove the upper paper deflector. See “Upper paper deflector assembly removal” on page 4-80. Release the pick roll retaining tab (A), and slide the pick roll off the shaft. MPF solenoid assembly removal Open the left door. Remove the MPF lower front cover.
Page 286

Press the clips on the end of the shaft to remove the MPF tires (B). Remove the C-clip (C) on the shaft. Remove the bushing (D). Note: The bushing fits into a detent (E) in the frame of the MPF arm assembly. Service Manual 4-64...
Page 287

Loosen the paper alignment screws (F). Remove the C-clip securing the MPF solenoid assembly on the shaft. Note: This C-clip is very difficult to locate and remove. Pull the shaft assembly (G) to the right until the left end of the shaft is clear of the frame, and slide the MPF solenoid assembly from the shaft.
Page 288

Installation note: Be careful not to lose the washer (H) that is between the MPF solenoid assembly and the C-clip. It belongs to the MPF arm assembly. Service Manual 4-66...
Page 289: Operator Panel Board Removal

Operator panel board removal When replacing any one of the following components: Warning: Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly • Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.
Page 290: Operator Panel Buttons Removal

Operator panel buttons removal The operator panel and navigation buttons are in a single kit. Remove the operator panel board. See “Operator panel board removal” on page 4-67. Remove the functional rubber sheet (A) and the rubber dome sheet (B). The navigation buttons and the select button can be removed by releasing the clips (C) on the back of the upper front cover.
Page 291: Outer Shield Removal

Outer shield removal Remove the left door. See “Left door removal” on page 4-7. Loosen the outer shield mounting screws (A), and remove the shield by sliding up. A(202) A(202) Repair information 4-69...
Page 292: Paper Alignment Assembly Removal

Paper alignment assembly removal Remove the upper paper deflector assembly. See “Upper paper deflector assembly removal” on page 4-80. Remove the inner paper deflector assembly. See “Inner paper deflector assembly removal” on page 4-48. Release the input paper sensor from its mounting, and remove. Remove the left door.
Page 293: Paper Bin Full Sensor Flag Removal

Paper bin full sensor flag removal Remove the left door. See “Left door removal” on page 4-7. Remove the redrive cap. See “Redrive assembly removal” on page 4-75. Remove the fuser wiper cover assembly. See “Fuser wiper cover assembly removal” on page 4-5 Remove the mounting screws (A) from the left side.
Page 294: Paper Size Sensing Board Removal

Paper size sensing board removal Remove the system board and inner shield. See “System board and inner shield removal” on page 4-77. Remove the paper size sensing board mounting screw (A). Disconnect the paper size sensing board cable (B) from the board. Remove the paper size sensing board from the latch (C).
Page 295: Power Takeoff Shaft And Spring Removal

Power takeoff shaft and spring removal Remove the power takeoff shaft and spring (A) through the bottom of the printer. Repair information 4-73...
Page 296: Printhead Removal

Printhead removal CAUTION: The laser scanning unit is not a serviceable FRU. Replace the entire unit when service is required. Remove the laser cover. See “Laser cover removal” on page 4-20. Disconnect the printhead cable (A) from the printhead assembly. Remove the three printhead mounting screws (B), and remove the printhead.
Page 297: Redrive Assembly Removal

Redrive assembly removal 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 4-75...
Page 298: Signature Button Contact Assembly Removal

Signature button contact assembly removal Remove the print cartridge. Remove the left side door. See “Left door removal” on page 4-7. Remove the right cover. See “Right cover removal” on page 4-9. Remove outer system board shield. See “Outer shield removal” on page 4-69.
Page 299: System Board And Inner Shield Removal

System board and inner shield removal When replacing any one of the following components: Warning: Operator panel assembly (or upper front cover) • System board assembly • Interconnect card assembly • Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.
Page 300: Toner Sensor Removal

Toner sensor removal Remove the right side cover. See “Right cover removal” on page 4-9. Remove the toner sensor mounting screw (A). Disconnect the toner sensor cable, and remove the toner sensor. Transfer roll assembly removal Be careful when handling the transfer roll. Wrap a piece of plain white paper around the charge roll Warning: to prevent contamination or damage.
Page 301: Upper Front Cover Hinge Assembly Removal

Upper front cover hinge assembly removal Remove the upper front cover. See “Upper front cover removal” on page 4-12. Remove the laser cover assembly. See “Laser cover removal” on page 4-20. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins, and remove the pins.
Page 302: Upper Paper Deflector Assembly Removal

Upper paper deflector assembly removal Either lift the ESD cover out of the way or remove it. See “ESD cover removal” on page 4-26. Note: The tabs holding the ESD cover are easily stressed or broken. Lift the left side to release the small tab (A) on the left and the MPF flag (B) and slide the upper paper deflector assembly to the right to unlatch the hooks (C) on the right.
Page 303: Connector Locations And Connections

5. Connector locations and connections Connections System board Connector locations and connections...
Page 304

System board (see “System board” on page 5-1) Connector Pin no. Signal J1 Interconnect card J2 Printhead (laser cable) VIDEO 1+ CN VIDEO 1- CN Ground LADJ2* VIDEO 0- CN VIDEO 0+ CN Ground +5PHEAD LPOW Ground LADJ* CN LPOW FB LENA* J3 Printhead (HSYNC)/mirror motor Ground...
Page 305

System board (see “System board” on page 5-1) Connector Pin no. Signal J7 USB port J8 Cover closed switch Cov Closed Ground +5V dc J10 Fuser DC NARMEDIA* Ground THERM Ground THUMP +5V dc THUMPRET EXIT SNS* +3.3 V dc I2C CLK L5 I2C DAT L5 J13 Operator panel...
Page 306

System board (see “System board” on page 5-1) Connector Pin no. Signal J15 HVPS ATSERVO TXENABLE 24 V dc switched CHARGE Ground Ground input sensor INPUTSENSX +5 V dc switched Cartridge toner wheel sensor +5 V dc TONER WHEELX Ground J16 Ethernet port J17 Parallel port J18 Front/bottom options...
Page 307

System board (see “System board” on page 5-1) Connector Pin no. Signal J21 Autoconnect—top Ground +5 V dc fused Ground +24 V dc PTC OPT J23 MPF pick solenoid MPFPick* +24V dc J24 Autocomp motor +24 V dc AUTOCOMP* J25 Autoconnect—bottom/front Ground +24VPTCOPT J26 Paper size sensor/autocomp motor...
Page 308

System board (see “System board” on page 5-1) Connector Pin no. Signal J27 LVPS (continued) HEAT HEAT Ground L FAN DRV* J28 MPF paper out MPF POUT Ground J29 Top options RXD1R Ground TXD1BR Ground J30 USB host–back USB host—front connection +5 V USBICN I–...
Page 309: Autoconnect

Autoconnect Connector Pin no. Signal (static) Bottom autoconnect +24 V dc 0 V dc +5 V dc 0 V dc 0 V dc 0 V dc Front autoconnect 0 V dc 0 V dc 0 V dc +5 V dc 0 V dc +24 V dc Top autoconnect...
Page 310: High-capacity Output Stacker Board

High-capacity output stacker board Connector Pin no. Signal +24 V dc Autoconnect Ground Prtxdin Ground prtrxd Ground +24 V dc Autoconnect Ground prtxdout Ground prtrxd Ground J3 Pass thru Ground sensor Paper Present RVsnsr J4 DC motor mtrout1 mtrout2 Ground Ground tach J5 Bin full/near...
Page 311: High Voltage Power Supply

High voltage power supply Connector CN no. Signal CN1 System board Developer PWM +24 V dc eturn Charge PWM +24 V dc TX PWM TX Enable TX CUR PWM SVRO OUT Interconnect card Connector Connector Pin no. Signal J1 1 J2 1 Connector locations and connections...
Page 312: Low Voltage Power Supply

Low voltage power supply CN pin Connector Signal CN1 Fuser lamp AC AC fuser lamp Not used AC fuser lamp CN2 DC output +5 V dc +5 V dc Ground Ground Ground Ground +24 V dc +24 V dc Heat on +5 V dc +5 V dc Ground...
Page 313: Output Expander Control Board

Output expander control board Connector Pin no. Signal +24 V dc Autoconnect Ground Prtxdin Ground prtrxd Ground +24 V dc Autoconnect Ground prtxdout Ground prtrxd Ground J3 Pass thru Ground sensor Paper Present RVsnsr J4 DC motor mtrout1 mtrout2 Ground Ground tach J5 Bin full/near...
Page 314: Staplesmart Finisher

StapleSmart finisher Connector Pin no. Signal Staple card assembly J1A Bottom +24 V dc autoconnect Ground J1B Bottom rtxdin autoconnect Ground prtrxd Ground Ground J2 Feed motor fdmtr1 fdmtr2 Ground Ground tachft 5Vptt J3 Stepper stpmtr- motor stpmtr- stpmtr+ stpmtr+ crtprsnt- stplow+ ‘stpphomo-...
Page 315

Connector Pin no. Signal Staple card assembly (continued) J7 Right side Ground sensor board Bottom Ground J8 Solenoid Sol2- +24 V dc J9 Bin empty Ground sensor bnempty- 5Vsnsr2 J10 Left side Ground sensor board full+ NRFull+ Ground J12 Pass thru Ground sensor psthruint...
Page 316

Service Manual 5-14...
Page 317: Preventive Maintenance

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-Dell attachments. • Lubrication specifications No requirements for this printer.
Page 318

Service Manual...
Page 319: Parts Catalog

PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet. • Model information used in the parts catalog. Model name Configuration Machine type Parts catalog Dell 5210n Network 4061-210 Dell 5310n Network 4061-410 Parts catalog...
Page 320: Assembly 1: Covers

Assembly 1: Covers Service Manual...
Page 321

• Right cable cover (1) • Left hinge spring (1) • Right hinge spring (1) 40X0010 Upper front cover assembly with Dell logo, including • Operator panel board (1) • Stop button (1) • Menu button (1) • Back button (1) •...
Page 322: Assembly 2: Frame 1

Assembly 2: Frame 1 Service Manual...
Page 323

Assembly 2: Frame 1 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X0065 Frame extension, nut plate, 200/210/400/410 40X0225 Right side hand holder Parts packet (PP 40X0165) 40X0024 Right frame extension, 200/210/400/410 40X0026 Right side frame ground contact 40X0025 Left frame extension, 200/210/400/410 40X0060...
Page 324

Assembly 3: Frame 2 Service Manual...
Page 325: Assembly 3: Frame 2

Assembly 3: Frame 2 Asm- Part Units/ Units/ kit Description Index number mach or pkg 3—1 40X0027 Upper redrive deflector 40X0028 Upper diverter spring Parts packet, redrive mounting screws (P/N 40X0253) 40X0029 Redrive assembly—250-sheet in/250 out, 000/010 40X0030 Redrive assembly—500-sheet in/500 out, 200/210/400/410 40X0032 Transfer deflector 40X0044...
Page 326

Assembly 4: Frame 3 Service Manual...
Page 327: Assembly 4: Frame 3

Assembly 4: Frame 3 Asm- Part Units/ Units/ kit Description Index number mach or pkg 4—1 40X0249 EP DC fan assembly, 200/210/400/410 40X0208 Blower duct, 200/210/400/410 Parts packet (PP 40X0165) Parts packet (PP 40X0165) 40X0034 Signature button sensor assembly 40X0035 EP DC fan assembly, 000/010 40X0033 Machine mounting pad...
Page 328: Assembly 5: Printhead

Assembly 5: Printhead Service Manual 7-10...
Page 329

Assembly 5: Printhead Asm- Part Units/ Units/ kit Description Index number mach or pkg 4—1 40X0061 Laser cable assembly Parts packet (printhead mounting screw) (PP 40X0165) 40X0062 Printhead assembly (includes all cables) CAUTION:The printhead is not a serviceable FRU. Do not disassemble the printhead.
Page 330: Assembly 6: Paper Feed-autocompensator

Assembly 6: Paper feed—autocompensator Service Manual 7-12...
Page 331

Assembly 6: Paper feed—autocompensator Asm- Part Units/ Units/ kit Description Index number mach or pkg 6—1 40X0066 Pick arm assembly—500-sheet, 200/210/400/410 40X0067 Pick arm assembly—250-sheet, 000/010 40X0068 Parts packet, bellcrank assembly—250-sheet tray, 000/010 • Bellcrank (1) • Spring (1) 40X0069 Parts packet, bellcrank assembly for—500-sheet tray, 200/210/400/410 •...
Page 332: Assembly 7: Paper Feed-multipurpose Feeder

Assembly 7: Paper feed—multipurpose feeder Service Manual 7-14...
Page 333

Assembly 7: Paper feed—multipurpose feeder Asm- Part Units/ Units/ kit Description Index number mach or pkg 7—1 40X0079 Multipurpose feeder lower deflector assembly 40X0310 Multipurpose feeder pick arm assembly with solenoid 40X0076 Pick roll assembly 40X0077 Multipurpose feeder paper out flag Parts packet (lower deflector mounting screw, 8 mm) (PP 40X0165) Parts packet (lower deflector mounting screw, 12 mm) (PP 40X0165) Parts packet (frame mounting screw) (PP 40X0165)
Page 334: Assembly 8: Paper Feed-alignment

Assembly 8: Paper feed—alignment Service Manual 7-16...
Page 335

Assembly 8: Paper feed—alignment Asm- Part Units/ Units/ kit Description Index number mach or pkg 8—1 40X0084 Paper feed alignment assembly paper feed Parts packet (clip ref ground mounting screw) (PP 40X0165) 40X0085 Reference ground clip 40X0086 Parts packet (reference adjust) •...
Page 336: Assembly 9: Integrated 250-sheet Paper Tray

Assembly 9: Integrated 250-sheet paper tray Service Manual 7-18...
Page 337

Assembly 9: Integrated 250-sheet paper tray Asm- Part Units/ Units/ kit Description Index number mach or pkg 9—1 40X3231 Integrated 250-sheet tray 40X0092 Side restraint—250-sheet tray 40X0093 Wear strips 40X0263 Pass thru plate—250-sheet tray 40X0094 Wear plate—250-sheet tray 40X0105 Restraint pad 40X0090 Back restraint—250-sheet tray Parts catalog...
Page 338: Assembly 10: Integrated 500-sheet Paper Tray

Assembly 10: Integrated 500-sheet paper tray Service Manual 7-20...
Page 339

Assembly 10: Integrated 500-sheet paper tray Asm- Part Units/ Units/ kit Description Index number mach or pkg 10—1 40X4663 Tray assembly—500-sheet tray 40X0099 Side restraint 40X0182 Wear strip 40X0103 Pass thru plate—500-sheet tray 40X0183 Wear plate—500-sheet tray 40X0105 Restraint pad 40X0106 Back restraint Parts catalog...
Page 340: Assembly 11: Drives-main Drive And Developer Drive

Assembly 11: Drives—Main drive and developer drive Service Manual 7-22...
Page 341

Assembly 11: Drives—Main drive and developer drive Asm- Part Units/ Units/ kit Description Index number mach or pkg 11—1 40X0107 Gearbox with motor 40X0110 Power takeoff shaft—250-sheet, 000/010 40X0111 Power takeoff shaft—500-sheet, 200/210/400/410 40X0112 Power takeoff shaft spring 99A0954 Bevel gear with grease packet and washer •...
Page 342: Assembly 12: Hot Roll Fuser

Assembly 12: Hot roll fuser Service Manual 7-24...
Page 343

Assembly 12: Hot roll fuser Asm- Part Units/ Units/ kit Description Index number mach or pkg 12—1 40X2592 Fuser assembly w/115 V lamp 40X2591 Fuser assembly w/100 V lamp 40X2590 Fuser assembly w/220 V lamp 40X0120 Fuser wiper cavity cover 40X0122 Fuser lamp, 115V 40X0123...
Page 344: Assembly 13: Transfer/charging

Assembly 13: Transfer/charging Service Manual 7-26...
Page 345

Assembly 13: Transfer/charging Asm- Part Units/ Units/ kit Description Index number mach or pkg 13—1 40X0126 Parts kit, charge roll link asm, left side 40X0127 Charge roll assembly, dual 40X0129 Parts kit, right side charge roll link assembly 40X0130 Transfer roll assembly 40X0131 Transfer roll assembly right arm 40X0132...
Page 346: Assembly 14: Electronics-power Supplies

Assembly 14: Electronics—power supplies Service Manual 7-28...
Page 347

Assembly 14: Electronics—power supplies Asm- Part Units/ Units/ kit Description Index number mach or pkg 14—1 40X4269 LVPS—115 V ac, 000/010 56P4233 LVPS—220 V ac, 000/010 40X4271 LVPS—115 V ac, 200/210/400/410 56P4238 LVPS—220 V ac, 200/210/400/410 40X0260 Power cord set (8 ft right angle, 13 amp)—United States, Canada, Caribbean countries, Colombia, Costa Rica, Dominican Republic, El Salvador, Ecuador, Guatemala, Honduras, Mexico, Nicaragua, Panama, Puerto Rico, Saudi Arabia, Venezuela, and Virgin Islands...
Page 348: Assembly 15: Electronics-card Assemblies

Assembly 15: Electronics—card assemblies Note: Service Manual 7-30...
Page 349

Assembly 15: Electronics—card assemblies Asm- Part Units/ Units/ kit Description Index number mach or pkg 15—1 40X0148 Interconnect card assembly (2 slot), 200/210/400/410 40X0147 Interconnect card assembly (1 slot), 000/010 40X5923 System board assembly (non-network), 000 40X5925 System board assembly (non-network), 200 40X5927 System board assembly (non-network), 400 40X5924...
Page 350: Assembly 16: Electronics-shields

Assembly 16: Electronics—shields Service Manual 7-32...
Page 351

Assembly 16: Electronics—shields Asm- Part Units/ Units/ kit Description Index number mach or pkg 16—1 40X0150 Outer shield—2 slot, 200/210/400/410 Parts packet (INA cover mounting screw) (PP 40X0165) Parts packet (outer shield mounting screw) (PP 40X0165) Parts packet (inner shield mounting screw) (PP 40X0165) 40X0149 Inner shield assembly—2 slot, 200/210/400/410 40X0153...
Page 352: Assembly 17: Cabling Diagrams 1

Assembly 17: Cabling diagrams 1 Asm- Part Units/ Units/ kit Description Index number mach or pkg 17—1 40X0223 HVPS/input sensor/toner sensor cable assembly 40X0160 MPF sensor cable 40X0264 Output bin sensor cable Service Manual 7-34...
Page 353: Assembly 18: Cabling Diagrams 2

Assembly 18: Cabling diagrams 2 Asm- Part Units/ Units/ kit Description Index number mach or pkg 18—1 40X0061 Laser printhead cable assembly 40X0074 Autocompensator motor cable 40X0046 Paper size sensing board/Tray 1 autocompensator paper out/low cable Parts catalog 7-35...
Page 354: Assembly 19: Cabling Diagrams 3

Assembly 19: Cabling diagrams 3 Service Manual 7-36...
Page 355

Assembly 19: Cabling diagrams 3 Asm- Part Units/ Units/ kit Description Index number mach or pkg 19—1 40X0034 Signature button contact assembly with cable 40X0156 Bottom/front autoconnect cable assembly 40X0223 HVPS/input sensor/toner sensor cable assembly 40X0157 Top autoconnect cable assembly 40X0224 LVPS to system board cable assembly Parts catalog...
Page 356: Assembly 20: Cabling Diagrams 4

Assembly 20: Cabling diagrams 4 Service Manual 7-38...
Page 357

Assembly 20: Cabling diagrams 4 Asm- Part Units/ Units/ kit Description Index number mach or pkg 20—1 40X0006 Upper front cover hinge assembly, includes: • USB cable (A) (1) • Operator panel cable (B) (1) • Cover open switch/cable (C) (1) 40X0162 System board to fuser board cable assembly 40X0163...
Page 358: Assembly 21: Cabling Diagrams 5

Assembly 21: Cabling diagrams 5 Service Manual 7-40...
Page 359

Assembly 21: Cabling diagrams 5 Asm- Part Units/ Units/ kit Description Index number mach or pkg 21—1 40X0083 Frame assembly with solenoid and cable 40X0159 Main drive motor cable assembly 40X0035 EP fan with cable—250 sheet, 000/010 40X0249 EP fan with cable—500 sheet, 200/210/400/410 40X0053 Main fan, 250 sheet 40X0054...
Page 360: Assembly 22: Optional 250-sheet Paper Drawer

Assembly 22: Optional 250-sheet paper drawer Asm- Part Units/ Units/ kit Description Index number option or pkg 22—1 40X3230 250-sheet paper drawer, complete assembly Parts packet, screw (switch spring) (PP 99A0263) 99A0063 Switch activate spring 56P4129 Paper out arm—250-sheet Parts packet, screw (auto comp mounting) (PP 99A0263) Parts packet (PP 99A0263) 40X3232 Pick arm assembly...
Page 361: Assembly 23: Optional 250-sheet Paper Tray

Assembly 23: Optional 250-sheet paper tray Asm- Part Units/ Units/ kit Description Index number option or pkg 23—1 40X3231 Tray assembly, option—250-sheet 40X3235 Side restraint—250-sheet tray 56P1279 Wear strips 56P4230 Clip—250-sheet pass thru 99A0121 Plate—250-sheet tray wear 99A0120 Restraint pad 40X3236 Back restraint—250-sheet tray Parts catalog...
Page 362: Assembly 24: Optional 500-sheet Paper Drawer

Assembly 24: Optional 500-sheet paper drawer Asm- Part Units/ Units/ kit Description Index number option or pkg 24—1 40X3243 Drawer and tray assembly, complete—500-sheet option Parts packet (auto comp mounting screw) (PP 99A0263) 40X3246 Pick arm assembly—500 sheet 56P1228 Bellcrank spring arm 56P2540 Bellcrank spring—500-sheet option tray 40X4308...
Page 363: Assembly 25: Optional 500-sheet Paper Tray

Assembly 25: Optional 500-sheet paper tray Asm- Part Units/ Units/ kit Description Index number option or pkg 25—1 40X4663 Tray assembly—500-sheet 56P4137 Side restraint—500-sheet tray 99A0292 Wear strips 56P4196 Pass thru plate 56P4195 Plate—500-sheet wear 99A0120 Restraint pad 56P4147 Back restraint—500-sheet tray Parts catalog 7-45...
Page 364: Assembly 26: Duplex Option

Assembly 26: Duplex option Asm- Part Units/ Units/ kit Description Index number option or pkg 26—1 56P4100 Duplex assembly.—250-sheet 56P4102 Duplex assembly—500-sheet Service Manual 7-46...
Page 365: Assembly 27: Envelope Feeder

Assembly 27: Envelope feeder Asm- Part Units/ Units/ kit Description Index number option or pkg 27—1 40X3248 Complete envelope option Parts catalog 7-47...
Page 366: Assembly 28: Output Expander 1

Assembly 28: Output expander 1 Asm- Part Units/ Units/ kit Description Index number option or pkg 28—1 40X3270 Complete output expander assembly 99A0104 Upper diverter spring Parts packet (PP 99A0263) 56P4198 Output expander tray 56P4163 Left side cover 40X3265 Bin full dual sensor upper stacker assembly Service Manual 7-48...
Page 367: Assembly 29: Output Expander 2

Assembly 29: Output expander 2 Asm- Part Units/ Units/ kit Description Index number option or pkg 29—1 40X3267 Rear access door assembly 56P4235 Right side cover Parts packet, screw (PP 99A0263) 40X3264 Output expander pass thru sensor Parts catalog 7-49...
Page 368: Assembly 30: High-capacity Output Expander 1

Assembly 30: High-capacity output expander 1 Asm- Part Units/ Units/ kit Description Index number option or pkg 30—1 40X3263 Complete high-capacity output expander 40X3267 Rear access door assembly 56P4211 Rear door latch 56P4204 Right cover 56P4205 Front cover 40X3268 Output tray assembly 56P4203 Left cover 56P4208...
Page 369: Assembly 31: High-capacity Output Expander 2

Assembly 31: High-capacity output expander 2 Asm- Part Units/ Units/ kit Description Index number option or pkg 31—1 99A0104 Upper diverter spring 99A0415 Swing arm spring Parts packet (PP 99A0263) 56P4212 Bin full dual sensor upper stacker assembly flag 40X3265 Bin full dual sensor upper stacker assembly 56P4210 Output spring...
Page 370: Assembly 32: High-capacity Output Expander 3

Assembly 32: High-capacity output expander 3 Service Manual 7-52...
Page 371

Assembly 32: High-capacity output expander 3 Asm- Part Units/ Units/ kit Description Index number option or pkg 32—1 40X3264 Stacker pass thru sensor Parts catalog 7-53...
Page 372: Assembly 33: 5-bin Mailbox 1

Assembly 33: 5-bin mailbox 1 Service Manual 7-54...
Page 373

Assembly 33: 5-bin mailbox 1 Asm- Part Units/ Units/ kit Description Index number option or pkg 33—1 40X3238 Complete 5-bin mailbox option 56P4176 Redrive cap cover 56P4180 Wire cover 56P4181 Top bin cover 56P4211 Rear access door latch 99A0104 Upper diverter spring 56P4183 Rear access door 56P4178...
Page 374: Assembly 34: 5-bin Mailbox 2

Assembly 34: 5-bin mailbox 2 Service Manual 7-56...
Page 375

Assembly 34 (cont.): 5-bin mailbox 2 Asm- Part Units/ Units/ kit Description Index number option or pkg 34—1 Parts packet (board mounting screw) (PP 99A0263) 40X2061 Diverter solenoid Parts catalog 7-57...
Page 376: Assembly 35: High-capacity Feeder 1

Assembly 35: High-capacity feeder 1 Service Manual 7-58...
Page 377

Assembly 35: High-capacity feeder 1 Asm- Part Units/ Units/ kit Description Index number option or pkg 35—1 40X3249 Complete option assembly (A4) 99A1818 Wear dimple strip 99A0681 Wear strip 40X3254 Front door assembly 56P4157 Door hinge Parts packet (6-32 hinge mounting nut) (PP 99A0676) Parts packet (hinge mounting flat washer) (PP 99A0677) Parts packet (hinge mounting star washer) (PP 99A0677) 40X3252...
Page 378: Assembly 36: High-capacity Feeder 2

Assembly 36: High-capacity feeder 2 Service Manual 7-60...
Page 379

Assembly 36: High-capacity feeder 2 Asm- Part Units/ Units/ kit Description Index number option or pkg 36—1 99A0654 Paper low switch Parts packet (nuts) (PP 99A0676) 40X3262 AC external jumper cord 40X2669 Power supply board Parts catalog 7-61...
Page 380: Assembly 37: High-capacity Feeder 3

Assembly 37: High-capacity feeder 3 Asm- Part Units/ Units/ kit Description Index number option or pkg 37—1 99A0275 Power takeoff spring 99A0272 Drive shaft—250-sheet Service Manual 7-62...
Page 381: Assembly 38: High-capacity Feeder 4

Assembly 38: High-capacity feeder 4 Asm- Part Units/ Units/ kit Description Index number option or pkg 38—1 Parts packet (auto comp assembly mounting screw) (PP 99A0263) 40X3255 Pick arm assembly—2000-sheet 40X4308 Pick roll assembly 40X3233 Option pass thru sensor Parts catalog 7-63...
Page 382: Assembly 39: Kiosk-vertical And Horizontal Paper Adapters

Assembly 39: Kiosk—vertical and horizontal paper adapters Asm- Part Units/ Units/ kit Description Index number option or pkg 39—1 40X3280 Complete vertical kiosk option 40X3269 Complete horizontal kiosk option Service Manual 7-64...
Page 383: Assembly 40: Staplesmart Finisher I

Assembly 40: StapleSmart finisher I Asm- Part Units/ Units/ kit Description Index number option or pkg 40—1 40X3273 Complete option 40X3276 Rear access door 56P4211 Rear access door latch 56P4214 Right base assembly cover 56P4216 Stapler access cover 40X3274 Stapler access door switch assembly 40X3277 Output assembly tray 40X1816...
Page 384: Assembly 41: Staplesmart Finisher 2

Assembly 41: StapleSmart finisher 2 Asm- Part Units/ Units/ kit Description Index number option or pkg 41—1 40X3278 Stapler assembly Service Manual 7-66...
Page 385: Assembly 42: Staplesmart Finisher 3

Assembly 42: StapleSmart finisher 3 Asm- Part Units/ Units/ kit Description Index number option or pkg 42—1 40X3279 Switch assembly, top cover open 99A0104 Spring, upper diverter Parts catalog 7-67...
Page 386: Assembly 43: Staplesmart Finisher 4

Assembly 43: StapleSmart finisher 4 Asm- Part Units/ Units/ kit Description Index number option or pkg 43—1 99A2480 StapleSmart wheels maintenance kit Service Manual 7-68...
Page 387: Assembly 44: Options

Assembly 44: Options Asm- Part Units/ Units/ kit Description Index number option or pkg 40X1508 128MB memory option 40X1509 256MB memory option 40X1510 512MB memory option 40X1564 32MB Flash card 40X1565 64MB Flash card 40X3212 Bar code card assembly 40X3378 IPDS SCS/Tne card assembly 40X0199 PrintCryption card assembly...
Page 388

Service Manual 7-70...
Page 389: Appendix A-options And Features

2000-sheet drawer, a duplex unit and an input option, or more than one input option. If you purchased an MFP that scans, copies, and faxes, you may need additional furniture. More information is available on the Dell Web site at www.dell.com. Install the printer and any options you have purchased in the following order: CAUTION: If you are installing options after setting up the printer, turn the printer off and unplug the power cord before continuing.
Page 390

Place the support unit on top of any previously installed drawers, or the table or printer cabinet where you plan to use the printer. The tab (A), round peg (B), and square holes (C) on top of any drawer help you position the support unit so the edges are aligned properly.
Page 391: Installing A Duplex Unit

Installing a duplex unit The duplex unit attaches under the printer, below the standard tray and above any drawers. Note: Two optional duplex units are available. The 250-sheet duplex unit only works with printers that have a 250-sheet standard tray, and the 500-sheet duplex unit only works with printers that have a 500-sheet standard tray.
Page 392: Installing Memory Or Option Cards

Installing memory or option cards CAUTION: If you are installing memory or option cards sometime after setting up the printer, turn the printer off and unplug the power cord before continuing. You can customize the printer memory capacity and connectivity by adding optional cards. The instructions in this section help you install any of the following options: Memory cards •...
Page 393: Accessing The Printer System Board

Accessing the printer system board You must access the printer system board to install printer memory, flash memory, a firmware card, or an option card. Note: Use a Phillips screwdriver to remove the system board access cover. Push the release latch, and lower the multipurpose feeder. Push the release latch, and open the top front cover.
Page 394

Slide the shield to the right, and then remove it. Set the shield aside. Use the illustration to locate the connector for the card you want to install. Firmware card connector Option card connectors Memory card connector Service Manual...
Page 395: Removing Or Installing A Memory Card

Removing or installing a memory card Removal Remove the system board access cover. (See “Accessing the printer system board” on page A-5.) Warning: Printer memory cards are easily damaged by static electricity. Touch something metal such as the printer frame before you touch a memory card. Push the latches away from the card on both ends of the memory card connector.
Page 396: Installation

Installation Note: Printer memory cards designed for other printers may not work with the printer. Remove the system board access cover. (See “Accessing the printer system board” on page A-5.) Warning: Printer memory cards are easily damaged by static electricity. Touch something metal such as the printer frame before you touch a memory card.
Page 397: Installation

Installation Note: Flash memory or firmware cards designed for other printers may not work with the printer. Remove the system board access cover. (See “Accessing the printer system board” on page A-5.) Note: If an option card has been installed, you may need to remove the option card before installing the flash memory or firmware card.
Page 398: Installing An Option Card

Installing an option card The printer has two connectors that support the following option cards: Hard disk with adapter card • MarkNet N8000 series internal print server • RS-232 Serial Interface Card • Parallel 1284-B Interface Card • Coax/Twinax Adapter for SCS •...
Page 399: Replacing The Shield

Replacing the shield After you have installed options on the printer system board, follow these steps to reattach the shield and close the doors. Align the keyholes on the shield with the screws on the frame. Slide the shield down onto the screws. Tighten the six screws (A).
Page 400

Canceling a job from the printer operator panel If the job is formatting or already printing, and Cancel a Job appears on the first line of the display: Press . A list of jobs appears. Press until appears next to the job requiring cancellation, and then press The message Canceling <filename>...
Page 401: Printing The Menu Settings Page

Canceling a job from a computer running Mac OS X When you send a job to print, the printer icon for your selected printer appears in the dock. Open Applications > Utilities, and then double-click Print Center or Printer Setup. Double-click the printer you are printing to.
Page 402: Printing A Font Sample List

Printing a font sample list To print samples of the fonts currently available for the printer: Make sure the printer is on and the Ready message appears. Press on the operator panel. Press until the appears next to Reports, and then press Press until the appears next to Print Fonts, and then press...
Page 403

Enter a User Name and PIN. Send your job to the printer. Go to the printer when you are ready to retrieve your confidential print job, and follow the At the printer steps. Macintosh From a word processor, spreadsheet, browser, or other application, select File > Print. In the Copies &...
Page 404

Printing and deleting held jobs Held jobs (Verify Print, Reserve Print, or Repeat Print) are printed or deleted from the printer operator panel and do not require a PIN number. Verify Print If you send a Verify Print job, the printer prints one copy and holds the remaining copies you requested in printer memory.
Page 405: Linking Trays

At the printer Press until the appears next to Held jobs, and then press Press until the appears next to your user name, and then press Press until the appears next to the type of action you want to perform, and then press Print All Delete All Print A Job...
Page 406: Identifying And Linking Output Bins

Identifying and linking output bins There is one standard output bin on all printer models. Depending on the model you selected, your output bin capacity is 250 or 500 sheets. If you need additional output capacity, there are several optional output bins available for your printer.
Page 407

Output bins (continued) Each bin accommodates How many Bin is Output can be allowed to Illustration of output bin Printer bin name installed on Print media connect with Models the printer Output • 650 sheets 5210n 1 5-bin expander (75 g/m ) of plain mailbox, 1 5310n...
Page 408: Linking Output Bins

Linking output bins Linking output bins lets you create a single output source so the printer can automatically switch output to the next available bin. You can also set the output type for media such as card stock or envelope sizes that cannot be sent to an optional output bin.
Page 409

Index upper front cover including buttons Numerics upper front panel button kit 1565 Emul Error Load Emul Option 2-42 250-sheet paper drawer, option 7-42 250-sheet paper tray, integrated 7-18 cable diagrams 7-34 7-35 7-36 7-38 7-40 250-sheet paper tray, option CACHE Test parts catalog 7-43...
Page 410

OUTPUT BIN TESTS Diverter Test 3-16 defaults Feed Test 3-14 EP defaults 3-22 Feed to All Bins 3-14 factory defaults 3-28 Sensor Tests 3-15 US/Non-US defaults 3-20 PRINT TESTS deflector input source inner paper deflector assembly 4-48 Prt Quality Pgs MPF lower paper deflector 4-62 PRINTER SETUP...
Page 411

finisher tests high-capacity feeder Feed Tests locations 3-17 Sensor Test parts catalog 3-17 7-58 7-60 7-62 7-63 flag service check 2-96 fuser exit sensor flag and spring high-capacity output expander 4-31 fuser narrow media flag and spring parts catalog 4-37 7-50 7-51 paper bin full sensor...
Page 412: Part Number Index

options descriptions Macintosh A-11 A-12 A-15 A-16 parts catalog 7-69 main drive assembly service checks 2-109 parts catalog 7-22 outer shield removal 4-58 parts catalog 7-32 service check 2-106 removal 4-69 main fan removal 4-57 output bin sensor tests maintenance 5-bin mailbox 3-16 ESD-sensitive parts...
Page 413

card assemblies 7-30 power supplies 7-28 quality pages 3-26 shields 7-32 Quick Disk Test 3-18 envelope feeder 7-47 Quick Test frame high-capacity feeder 7-58 7-60 7-62 7-63 high-capacity output expander redrive assembly 7-50 7-51 hot roll fuser parts catalog 7-24 integrated paper tray—250-sheet removal 7-18...
Page 414

MPF pick tire removal main fan 4-63 2-76 MPF solenoid assembly operator panel 4-63 2-107 MPF⁄lower front cover assembly options 4-16 2-109 operator panel board removal output bin sensor 4-67 2-110 operator panel buttons output expander 4-68 2-111 outer shield paper feed 4-69 2-113...
Page 415

theory of operation autocompensator 3-31 autoconnect cabling and connectors 3-32 duplex unit 3-32 option microcode 3-32 toner sensor removal 4-78 tools 1-20 Top Margin duplex 3-10 simplex (front side) transfer roll assembly parts catalog 7-26 removal 4-78 service check 2-129 transparencies 1-17 tray linking...
Page 416

Service Manual...
Page 417: Part Number Index

Operator panel outer bezel with Dell logo, 5210n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 418

40X0057 Output paper level flag, 000/010 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 40X0058 Output paper level flag, 200/210/400/410 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7 40X0059...
Page 419

Operator panel outer bezel with Dell logo 5210n - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 420

40X0271 Power cord set—Hong Kong - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29 40X0272 Power cord set—Japan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29 40X0280...
Page 421

40X3263 Complete high-capacity output expander - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-50 40X3264 Output expander pass thru sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-49 40X3264...
Page 422

56P4210 Output spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-51 56P4211 Rear access door latch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55 7-65...
Page 423

Print defects guide Page 1 of 1 Print defects guide Match a set of repeating defects on a print job to the marks on one of the vertical lines. The line that best matches the defects on the print job indicates which particular part may be causing the defect. For example, the distance between these two marks represents a repeating defect that occurs every 28.3 mm (1.11 in.), which means the charge rollers may need to be replaced.
Page 424

Dell 5210n/5310n (4061) Wiring diagram Printhead Cover Closed Cartridge Main Fan Switch STD Bin Autoconnect Sensor Fuser Fuser Lamp HOP LED HOP FULL* CN 12C DAT LS 12C CLK LS USB Board 3.3VDC USB Device Port ExitSens* Thumpret COV CLOSE...
Page 425

Dell 5210n : Recommended Spare-parts List 22 Dec 2010 Dell P/N MFG Part Description Dell Part Description or FRU Accessory GD531 CTRG,TONR,10K,U/R,5210/5310 Toner Cartridge, 10K Use/RTN toner GD711 ASSY,DRWR,SHEET,500,5210/5310 500-Sheet Paper Tray & Drawer Combo GD712 ASSY,DPLXR,SHEET,500,5210/5310 Duplex assembly500-sheet GD713...
Page 426

Mechanical/Chassis DG640 ASSY,PK ARM,BELLCRANK,5210/531 Integrated Tray Autocompensator Assy (includes Pick Arm Assembly - pick roll assembly, paper out flag, paper low/out sensor card assembly, Bellcrank assembly w/ spring, Autocompenator Cable and Screw) DG641 FDR,DFLR,LWR,MPF,5210/5310 Lower Deflector Assembly (includes: MP feeder lower deflector assembly, MP feeder Assy, Arm, Brushing, Frame Assy w/ Soleniod, Pick Roll Assy, MP paper out flag, Screws for lower deflector mounting [8 &...
Page 427

FG363 ASSY,CVR,CAP,REDRIVE,5210/5310 Redrive Cap GG201 ASSY,CVR,WIPER,FUSER,5210/5310 Fuser Wiper Cover HG124 CVR,LAMINATED,RT,5210/5310 Right Side Cover (w/screws) HG127 HLDR,SUPPORT,PAPER,5210/5310 Paper Support HG132 CVR,FRONT,LOWER,5210/5310 Lower Front Cover HG360 DOOR,CVR,LF,OTR,5210/5310 Left Door Assy (inner and outer assembled), Small access door HG567 PNL,DFLTR,INR,5210/5310 DEFLECTOR PANEL, Fuser Tansfer Plate JG092 ASSY,CVR,LASER,250,5210/5310 Laser Cover (w/ 5 laser cover mounting screws)
Page 428

Dell 5310n : Recommended Spare-parts List 22 Dec 2010 Dell P/N MFG Part Description Dell Part Description CRU or Accessory GD531 CTRG,TONR,10K,U/R,5210/5310 Toner Cartridge, 10K Use/RTN toner GD711 ASSY,DRWR,SHEET,500,5210/5310 500-Sheet Paper Tray & Drawer Combo GD712 ASSY,DPLXR,SHEET,500,5210/5310 Duplex assembly500-sheet GD713...
Page 429

JD308 KIT,DOC/DSK,PUB,EFIGS,52/5310N English, French, Italian, German, Spanish Doc kit with CD Heatsinks, Fans and Accessories DG915 FAN,CTRG,TONR,5210/5310 Toner Cartridge Blower/Fan (5310N) GG021 ASSY,FAN,MAIN,5210/5310 Main Fan (Includes: Fan Cap, Screw, Main Fan with Cable) Mechanical/Chassis DG640 ASSY,PK ARM,BELLCRANK,5210/531 Integrated Tray Autocompensator Assy (includes Pick Arm Assembly - pick roll assembly, paper out flag, paper low/out sensor card assembly, Bellcrank assembly w/ spring, Autocompenator Cable and Screw)
Page 430

GD715 CRD,WRLES,5210/5310N,DAO Wireless Card DAO KC516 CRD,WRLES,5210/5310N,EMEA Wireless Card EMEA NJ646 CRD,NTWK,COMM,ENET,5210N/5310N GIGABIT ETHERNET CARD, 52/5310N (option item). See also FG591 (System board with integrated Ethernet). Plastics DG916 LEVER,FLAG,LVL,POUT,250 Paper Bin Full Sensor Flag FG363 ASSY,CVR,CAP,REDRIVE,5210/5310 Redrive Cap GG201 ASSY,CVR,WIPER,FUSER,5210/5310 Fuser Wiper Cover HG008 BZL,PNL,OP,5310...

This manual also for:

5210n, 5310n