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• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Edition: August 30, 2007
Lexmark™ E250d and E250dn
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.
4512-220
4512-230

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  • Page 1

    Lexmark™ E250d and E250dn 4512-220 4512-230 • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

  • Page 2

    6000-XXX...

  • Page 4

    Improvements or changes in the products or the programs described may be made at any time. Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

  • Page 5: Table Of Contents

    4512-220, -230 Table of contents Table of contents ............v Notices and safety information .

  • Page 6: Table Of Contents

    How to use this parts catalog ............7-1 Lexmark™ E250d and E250dn...

  • Page 7: Notices And Safety Information, Laser Notice

    4512-220, -230 Notices and safety information The following laser notice labels may be affixed to this printer as shown: 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.

  • Page 8

    5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser. viii Lexmark™ E250d and E250dn...

  • Page 9

    4512-220, -230 Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.

  • Page 10

    4512-220, -230 Lexmark™ E250d and E250dn...

  • Page 11: Safety Information

    4512-220, -230 Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.

  • Page 12

    Antes de começar, desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para realizar a tarefa necessária. Lexmark™ E250d and E250dn...

  • Page 13

    4512-220, -230 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. •...

  • Page 14: Preventive Maintenance, Lubrication Specifications, Parts Catalog

    CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task. Lexmark™ E250d and E250dn...

  • Page 15: General Information, Models, Maintenance Approach

    4512-220, -230 1. General information are monochrome laser printers designed for single users or small The Lexmark™ E250d and E250dn workgroups. This book contains information on E250n and E250dn. For information on E352dn, see the 4512-430 service manual. Models There are two models covered in this manual: •...

  • Page 16: Overview Of The Operator Panel, Models E250d And E250dn

    • Press and release Cancel to cancel the job currently printing. • Press and hold Cancel until all of the lights come on to reset the printer. Lexmark™ E250d and E250dn...

  • Page 17: Specifications, Memory, Print Speed, Print Quality

    4512-220, -230 Specifications Memory 4512-220 4512-230 Item Lexmark Lexmark E250d E250dn Standard DRAM 32MB 32MB ✔ ✔ Optional SDRAM 32MB ✔ ✔ Optional SDRAM 64MB Optional SDRAM 128MB Optional SDRAM 256MB Maximum DRAM 96MB 96MB Optional flash memory 32MB Optional font cards (DBCS)

  • Page 18: Media Trays And Supply Capacity

    3,500 standard pages after market¹ High yield toner cartridge Photoconductor kit Up to 30,000 ² Up to 30,000 ² ¹ Declared value in accordance with ISO/IEC 19752 ² Based on approximately 5% coverage, actual yield may vary Lexmark™ E250d and E250dn...

  • Page 19: Connectivity And Compatibility

    4512-220, -230 Connectivity and compatibility 4512-220 4512-230 Item Lexmark Lexmark E250d E250dn Data stream emulations ✔ ✔ PCL 6 ✔ PostScript 3 (Mac only) ✔ ✔ PPDS Compatibility Windows/Macintosh/Linux¹ Windows/Macintosh/Linux¹ Standard local connections ✔ ✔ Parallel (IEE 1284 Bi-Di) ✔...

  • Page 20: Types Of Print Media

    24# envelopes. Use envelopes that lay flat when individually placed on a table face-down. The distance of any edge or corner from the table should be less than 3 mm. This refers to paper only. Treeing may occur on 16# paper. Input using manual feeder is reduced to 1/2 speed Lexmark™ E250d and E250dn...

  • Page 21: Tips On Preventing Jams, Paper Path

    4512-220, -230 Tips on preventing jams Paper path *Measurements are approximate paper lengths (millimeters) **Sensors are measured at rotation/position which they are tripped Paper path 117.8 Manual feed sensor Upper end feed rolls 60.5 Input sensor 49.0 Transfer roll 110.7 Fuser 26.9 Fuser exit rolls...

  • Page 22: Tools

    Have any exposed adhesive when the flap is in the sealed position • Use only recommended media. Refer to the Card Stock & Label Guide available on the Lexmark Web site at www.lexmark.com for more information about which media provides optimum results for the current printing environment.

  • Page 23: Acronyms

    4512-220, -230 Acronyms Autocompensator Mechanism (or paper feed) Analog-to-digital Converter ASIC Application Specific Integrated Circuit Complete Bill Of Material Cyclic Redundancy Check DIMM Dual In-Line Memory Module EEPROM Erasable Electrically Programmable Read-Only Memory External Network Adapter Field Replaceable Unit Host Based Printing HVPS High Voltage Power Supply Liquid Crystal Diode...

  • Page 24

    4512-220, -230 1-10 Lexmark™ E250d and E250dn...

  • Page 25: Diagnostic Information, Start

    4512-220, -230 2. Diagnostic information Start CAUTION: Unplug power from the printer before connecting or disconnecting any other cable, assembly, or electronic card. This is a precaution for personal safety and to prevent damage to the printer. This chapter contains the codes and diagnostic tools to aid in providing corrective action for a malfunctioning printer.

  • Page 26: Power-on Self Test (post) Sequence, Light Patterns And Error Messages

    “Service codes” on page 2-23. Note: If data is sent to the printer and all lights flash immediately, and double-clicking does not change the display, there may be a code problem. Contact the next level of support. Lexmark™ E250d and E250dn...

  • Page 27: Common Primary Light Patterns

    4512-220, -230 Common primary light patterns “Overview of the operator panel” on page 1-2 for icon information. Light on Light off ✷ Light blinking Light blinking slowly Common light sequences Printer Condition Page Ready / Power Saver ✷ Busy Hex Trace Ready Waiting ✷...

  • Page 28: Primary Codes, Hex Trace Ready

    • Advance users can use Hex Trace to help troubleshoot printing problems. After resolving the problem, turn off the printer to exit Hex Trace. Wait for the message to clear. • Press and hold Cancel to reset the printer. Lexmark™ E250d and E250dn...

  • Page 29: Not Ready

    4512-220, -230 Waiting Meaning The printer is waiting until a print timeout occurs, or until it receives additional data. Action • Press Continue to print the contents of the print buffer. • Press and release Cancel to cancel the print job. •...

  • Page 30: Close Door

    • The printer is resetting to the user default settings. Any active print jobs are canceled. A user default setting remains in effect until it is changed or has restored the factory default settings. Action Wait for the message to clear. Lexmark™ E250d and E250dn...

  • Page 31: Load Manual Feeder, Toner Low

    4512-220, -230 Load print media Meaning The printer is out of print media at the indicated source. Action • Load print media into the indicated tray, and press Continue to resume printing. • Press Cancel to reset the printer. Load manual feeder Meaning The printer prompts to load a single sheet of print media in the manual feeder.

  • Page 32

    The photoconductor kit is full and must be replaced. The printer will not print any more pages until the photoconductor kit is replaced. Action • Press and release Continue to print a photoconductor kit instruction page. • Replace the photoconductor kit. Lexmark™ E250d and E250dn...

  • Page 33

    4512-220, -230 Programming engine code/Programming system code Meaning New code is being programmed into the engine or firmware code flash. Action Wait for the message to clear. When the printer has finished programming the code, it performs a soft reset. Invalid engine code/Invalid network code Meaning The engine code and/or the network code has not been programmed or has been programmed but is invalid.

  • Page 34: Printer Error, Paper Jam Printer Error

    • Open the front door, clear the paper path, and close the door to resume printing. • Press Continue to clear the light sequence and continue printing. • Press Cancel to cancel the print job. 2-10 Lexmark™ E250d and E250dn...

  • Page 35: Output Bin Full

    4512-220, -230 Output bin full ✷ Meaning The output bin is full. Action • Remove printed pages from the output bin. • Press Continue to clear the error code. 2-11 Diagnostic information...

  • Page 36: Common Secondary Light Patterns

    Paper jam in the 550-sheet drawer ✷ ✷ Paper jam (duplex) ✷ Paper jam (duplex front) ✷ Paper jam (duplex rear) ✷ Paper jam (duplex - location unknown) ✷ ✷ Paper jam (duplex - unsupported size) 2-12 Lexmark™ E250d and E250dn...

  • Page 37: Table Of Contents

    4512-220, -230 When the Error and Continue lights are both on, a printer error has occurred with a secondary code. Press and release Continue twice quickly to display the secondary error code light sequence. The following table shows what these light sequences mean and where to go for help. Secondary light sequences (printer errors) Printer Condition Page...

  • Page 38: Secondary Error Codes

    A paper jam has occurred. The jammed media is most likely in the fuser area under the toner cartridge assembly. Action Clear the paper jam. Paper jams as a printed job exits the printer Meaning A paper jam has occurred as the print media is exiting the printer. Action Clear the paper jam. 2-14 Lexmark™ E250d and E250dn...

  • Page 39

    4512-220, -230 Paper jam in the 250-sheet tray Meaning A paper jam has occurred in the 250-sheet tray. Action Clear the paper jam. Paper jam in the 550-sheet drawer Meaning A paper jam has occurred in the 550-sheet drawer. Action Clear the paper jam.

  • Page 40

    Remove the tray, open the duplex door and clear the paper jam. Paper may also be inside the rear door. Paper jam (duplex - unsupported size) ✷ ✷ Meaning A paper jam has occurred in the duplex unit due to an unsupported print media size. Action Clear the paper jam. 2-16 Lexmark™ E250d and E250dn...

  • Page 41: Complex Page, Insufficient Collation Area

    4512-220, -230 Complex page Meaning The page may not print correctly because the print information on the page is too complex (that is, too large for the printer memory). Action • Press Continue to clear the error code and continue processing the print job (some of the print data may be lost).

  • Page 42: Network Interface Errors, Font Error

    The printer does not have enough memory to save the data in the buffer. Action • Install additional memory. • Press Continue to continue printing the job. • Press Cancel to cancel the print job. 2-18 Lexmark™ E250d and E250dn...

  • Page 43: Insufficient Defrag Memory, Ena Connection Lost, Host Interface Disabled

    4512-220, -230 Insufficient defrag memory ✷ Meaning The printer memory does not have the free space necessary to collate the print job. This may happen due to one of these errors: • Memory is full. • A page is too complex to print. •...

  • Page 44: Memory Full, Invalid Engine Code

    • Press Cancel to cancel the print job. Invalid engine code Meaning The engine code has not been programmed, or the programmed code is not valid. Action Download the valid engine code to the internal print server. 2-20 Lexmark™ E250d and E250dn...

  • Page 45: Invalid Network Code

    4512-220, -230 Invalid network code ✷ Meaning The code in an internal print server had not been programmed, or the programmed code is not valid. Action Download the valid engine code to the internal print server. Toner cartridge region mismatch ✷...

  • Page 46: Unsupported Toner Cartridge, Too Many Options Attached

    • Remove the toner cartridge, and replace it with a supported toner cartridge. • Turn the printer back on. Too many options attached Meaning This message refers to too many flash options. Action Press Continue briefly to clear the message. 2-22 Lexmark™ E250d and E250dn...

  • Page 47: Service Codes, Unsupported Flash Option

    4512-220, -230 Unsupported flash option Meaning An error occurs at power-on. Action Power off the printer and remove the unsupported option Service codes All service errors are indicated by all lights flashing as the primary notification or code. The secondary light pattern indicates an area or function which has the error.

  • Page 48

    ✷ 92x–Fuser or toner sensor ✷ ✷ ✷ 93x–Printhead, drive motor ✷ ✷ 94x–LVPS service error 95x–Controller card (NCRAM, ✷ ✷ ✷ ROM, or NAND) ✷ ✷ ✷ 96–RAM memory ✷ ✷ ✷ ✷ 97x–Network 2-24 Lexmark™ E250d and E250dn...

  • Page 49

    4512-220, -230 Service tertiary error codes Service tertiary error codes Service error codes are generally non-recoverable except in an intermittent condition when POR (power-on reset) is performed which allows the printer to temporarily recover from the error. Note: All service errors are initially communicated by all lights flashing which is the primary indication or code. For brevity, this indication is not repeated in the following codes.

  • Page 50

    923–Fuser too hot during printing ✷ ✷ ✷ or idle 924–Open circuit in thermistor ✷ ✷ path ✷ ✷ ✷ 925–Incorrect fuser ✷ ✷ ✷ ✷ 927–Fan stalled 929–Toner sensor or toner ✷ ✷ ✷ cartridge are bad 2-26 Lexmark™ E250d and E250dn...

  • Page 51

    4512-220, -230 Printhead, transport motor, or RIP/engine communication error Codes 930 through 935 indicate a problem with the printhead. Check cables to the printhead. Replace the printhead as necessary. Codes 936 and 937 indicate a problem in the drive system motor. Code 939 indicates a communication failure between the RIP and engine processors.

  • Page 52

    Service tertiary codes–network error ✷ ✷ ✷ 975–Unrecognizable network port 976–Unrecoverable software error ✷ ✷ ✷ in network port 978–Bad checksum while ✷ ✷ programming port 979–Flash parts failed while ✷ ✷ ✷ programming port 2-28 Lexmark™ E250d and E250dn...

  • Page 53: Messages And Error Codes, User Attendance Messages, Paper Jam Error Codes

    4512-220, -230 Messages and error codes Note: The following message and error codes will be visible only in the print history in the diagnostic mode for E250d and E250dn. See “Diagnostics mode selections” on page 3-8. The printer operator panel displays light patterns describing the current state of the printer and indicates possible printer problems that must be resolved.

  • Page 54

    Timeout on data collection during auto alignment 200.38 Interpage servo gap is smaller than expected for printhead offset target evaluation 201.00 Paper jam between input and exit sensor 201.01 Transport motor identification failed to identify either motor after two tries. 2-30 Lexmark™ E250d and E250dn...

  • Page 55

    4512-220, -230 Paper jam error codes (Continued) Error Description 201.02 Exit sensor never made by leading edge of page. Also known as internal jam. 201.03 Video never started on the page at the input sensor within two inches after hitting the input sensor 201.05 Restart attempted after an internal jam without the cover open/close event.

  • Page 56

    Second pick from manual feeder, tray 1, or feeder failed when media was in the source while the other sheets were committed to the paper path. 251.19 Media never reached the input sensor from the manual feeder. 2-32 Lexmark™ E250d and E250dn...

  • Page 57: Service Error Codes

    4512-220, -230 Service error codes Service error codes are generally non-recoverable except in an intermittent condition when POR is performed and the printer can temporarily recover from the error condition. Service error codes (9xx) Error Description Engine software service errors 902.xx Engine software error Transfer service errors...

  • Page 58

    Printhead sweep error, fwd and rev capture times differ by too much 935.23 Printhead sweep error, check sweep accuracy state 935.24 Printhead sweep error, reserved 935.25 Printhead sweep error, detected resonant frequency out of expected range 2-34 Lexmark™ E250d and E250dn...

  • Page 59

    4512-220, -230 Service error codes (9xx) (Continued) Error Description 935.26 Printhead sweep error, timed out waiting for end of sweep Transport motor service errors 936.01 No lock detected at normal motor start 936.02 No lock detected at motor start for motor ID 936.03 No halls detected at motor start 936.04...

  • Page 60: Diagram Of The Printer Menus

    Character Set Advanced Status Mac Binary PS Mac Binary PS Best Fit Protocol Std Net Setup Tray 1 Renumber Honor Init Auto CR after LF Parallel Mode 2 Auto LF after CR MAC Binary PS 2-36 Lexmark™ E250d and E250dn...

  • Page 61: Symptom Tables, Post Symptom Table

    4512-220, -230 Symptom tables POST symptom table Note: Investigate any displayed codes before proceeding with these symptoms. For example, a missing toner cartridge will prevent POST from completing. Symptom Action The main motor, cooling fan, and fuser do not come “Cover interlock switch service check”...

  • Page 62: Printer Symptom Table

    “Media “trees,” wrinkles, stacks poorly, or curls” on page 2-45. Print quality problems “Solving print quality problems” on page 3-50. • Light print • Blurred characters • Toner on both sides of media • Toner not fused • Streaks • Blank pages 2-38 Lexmark™ E250d and E250dn...

  • Page 63: Service Checks, Controller Card Service Check

    4512-220, -230 Service checks Service checks which involve measuring voltages on the LVPS/HVPS (low voltage power supply/ high voltage power supply board) should be performed with the printer positioned on its back side. Note: When making voltage readings, always use frame ground unless another ground is specified. See the wiring diagram in the back of the book for more information.

  • Page 64: Cooling Fan Service Check, Cover Interlock Switch Service Check

    • If both pass continuity, turn the printer on, and measure +5 V dc on pin 2 at J6 on the controller card. • Verify pin 3 at J6 is ground. • If voltage or ground is not present, see “Controller card service check” on page 2-39 for more information. 2-40 Lexmark™ E250d and E250dn...

  • Page 65: Dead Machine Service Check, Fuser Service Check

    4512-220, -230 Dead machine service check CAUTION: Check the AC line voltage. The voltage should be within the following limits: • 100 V ac (volts alternating current) — 127 V ac for the 110 V printer • 200 V ac — 240 V ac for the 220 V printer Action Unplug the printer.

  • Page 66: Lvps/hvps Service Check, Main Motor Service Check

    • If these voltages are not correct, see “Controller card connector pin values” on card. Settings are lost page 5-2, or replace the controller card. See “Controller card removal” on page 4-13. when both are new and replaced at the same time. 2-42 Lexmark™ E250d and E250dn...

  • Page 67: Operator Panel Service Check, Paper Feed Service Checks

    4512-220, -230 Operator panel service check Inspect the operator panel cable for damage. Make sure the cable is plugged in securely. Run POST, and check each light for proper operation. See “Power-On Self Test (POST) sequence” on page 2-2. LED Operator panel service check Action Operator panel (LED) Lights...

  • Page 68

    • If it is not, replace the solenoid assembly. • If the resistance is 180—250 ohms, check the controller card. See “Controller card service check” on page 2-39 for more information. Replace controller card as necessary. 2-44 Lexmark™ E250d and E250dn...

  • Page 69: Parallel Or Usb Port Service Check

    4512-220, -230 Media skews Action Paper feed (pick tires) tray 1 Check tires for debris. If tires are new, try reversing each on its hub. Paper feed (pick tires) tray 2 Tray 1 Check side guides on Tray 1 and Tray 2. Guides set for a full stack of media Tray 2 (option) may be too wide when the stack is short.

  • Page 70: Print Quality Service Checks

    • If there is not continuity, call the next level of service. Try a different toner cartridge and PC kit. • If those fail, replace the LVPS/HVPS, controller card, or the printhead in that order. Also, see “Solving print quality problems” on page 3-50. 2-46 Lexmark™ E250d and E250dn...

  • Page 71

    4512-220, -230 Black page Note: Incorrect laser exposure or incorrect charging of the photoconductor causes an all black page. Always verify the same results from a different toner cartridge assembly and developer before proceeding. Action Toner electrodes (not a Check the three rearward electrodes below the toner cartridge assembly for contamination FRU) or damage.

  • Page 72

    See“LVPS/HVPS service check” on page 2-42 for more information. Try changing the setting to heavier paper or even card stock.1 Media (not a FRU) Make sure recommended media is being used. Check the media settings in the printer driver. 2-48 Lexmark™ E250d and E250dn...

  • Page 73

    4512-220, -230 Light print Action Toner cartridge (not a Make sure the toner cartridge and PC Kit are installed correctly and that the toner cartridge FRU) is not low on toner. If the problem continues, install a new toner cartridge. Recheck condition before replacing PC Kit, if necessary.

  • Page 74

    Replace as needed. If the lines are parallel and match the two intended ghost images, the Form Type may be incorrectly set. Check those settings. The PC cleaner sump may be full. Replace the PC kit. 2-50 Lexmark™ E250d and E250dn...

  • Page 75

    4512-220, -230 Print quality problems (Continued) Problem Cause/action Toner smears or rubs • Toner is not being fused to the paper. Replace the fuser. off the page. • Change the media texture setting in the driver. If special media is being used, such as card stock or labels, be sure to select the correct media type.

  • Page 76

    • Clear all jams. has been cleared. • Press and release , or open and close the printer cover to restart the printer. • Make sure the toner cartridge assembly is installed properly. 2-52 Lexmark™ E250d and E250dn...

  • Page 77: Printhead Service Check, Transfer Roll Service Check

    4512-220, -230 Print quality problems (Continued) Problem Cause/action Unexpected • Ensure correct printer driver is being used. characters print or • Select hex trace mode to determine what the problem is. characters are • Restore factory defaults. missing. • Make sure the parallel cable or USB cable is firmly plugged in at the back of the printer. Jobs are not printing, •...

  • Page 78

    4512-220, -230 2-54 Lexmark™ E250d and E250dn...

  • Page 79: Diagnostic Aids, Accessing Service Menus, Printing Menus, Moving Around The Menu

    4512-220, -230 3. Diagnostic aids Accessing service menus Enter Configuration Menu 1. Turn off the printer. The Configuration menu group contains a set of menus, settings and operations which are 2. Open the front access cover and infrequently required by a user. Generally, the turn on the printer while pressing options made available in this menu group are and holding...

  • Page 80

    4512-220, -230 Configuration Menu printout sample Note: The light sequences change relative to the option on the printer. Lexmark™ E250d and E250dn...

  • Page 81

    4512-220, -230 Diagnostics mode printout sample Note: The light sequences change relative to the options on the printer. Diagnostic aids...

  • Page 82: Configuration Menu Selections, Utilities

    • One page is gray with graphics, one is black, and one is blank. Reset Photo- Return the photoconductor counter to zero. conductor Counter The replace photoconductor message should be cleared only when the photoconductor kit has been replaced. Lexmark™ E250d and E250dn...

  • Page 83: Setup, Parallel

    4512-220, -230 Setup Use the Setup menu to configure how the printer formats the end of a line depending on the computer system being used. Menu item Use setting to Values Demo Mode Put printer into demo mode where internal sheets print with each Deactivate (default) press of Activate...

  • Page 84

    On–The printer processes raw binary PostScript print jobs from computers using the Macintosh operating system. This setting often causes Windows print jobs to fail. Auto (default)–The printer processes print jobs from computers using either Windows or Macintosh operating systems. Lexmark™ E250d and E250dn...

  • Page 85: Network

    4512-220, -230 Network Use the network menu to change printer settings on jobs sent through a network port (either standard network or network opt <x>). Menu item Use setting to Values NPA Mode Send print jobs to the printer and query printer status information simultaneously.

  • Page 86: Diagnostics Mode Selections

    Allow the printer ID to match the label ID after the controller card is replaced. 000101 (default) 000189 Printer alignment A step-by-step process to align a new printhead. See “Printhead assembly None electronic adjustment” on page 3-9 for more information. Lexmark™ E250d and E250dn...

  • Page 87: Adjustment Procedures

    4512-220, -230 Adjustment procedures Printhead assembly electronic adjustment Note: Before aligning the printhead electronically, first align the printhead mechanically, if needed. See “Printhead assembly mechanical adjustment” on page 3-13. Press and hold until all of the lights cycle to print the menu sheet and Step 1 test page. Step 1 printout (sample only;...

  • Page 88

    <CA> light sequences on the right side of Step 2 test page. Press and release to change the <CA> light sequence to the number beside the darkest portion of the vertical bar. See note on page 3-9. See note on page 3-9. <CA> 3-10 Lexmark™ E250d and E250dn...

  • Page 89

    4512-220, -230 Press and hold until all of the lights cycle to print Step 3 test page. Step 3 printout (sample only; use actual sheet) Press and release to change the <BA> light sequence to the number beside the darkest portion of the vertical bar.

  • Page 90

    Note: The load/remove paper light will be displayed to indicate that the final level of the menu has been reached. Verify that the overall darkest line across the page is “0.” If not, then run the alignment again. Turn the printer off to exit the printer alignment menu. 3-12 Lexmark™ E250d and E250dn...

  • Page 91

    4512-220, -230 Printhead assembly mechanical adjustment A printhead needs to be correctly positioned after it has been removed. Align it to the frame or use the same position as the removed printhead. An indicator is located at the front right-hand screw for reference. Note: Skew is caused by a sheet being fed through the printer while misaligned.

  • Page 92

    After obtaining a properly adjusted image on the paper, tighten all three screws. Note: The printhead must be aligned electronically. See “Printhead assembly electronic adjustment” on page 3-9. 3-14 Lexmark™ E250d and E250dn...

  • Page 93: Repair Information, Handling Esd-sensitive Parts, Removal Procedures

    4512-220, -230 4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic cards: •...

  • Page 94

    Extract the cable, and unhook the access cover by pressing the right hinge to the right until it can be lifted up and away from its pivot. Relax the hinge above the pivot. In the same manner, move the left hinge from its pivot point. Lexmark™ E250d and E250dn...

  • Page 95

    4512-220, -230 Tilt the front cover down, and disconnect it on the left side from the link. Warning: Make sure that the link is not bent or pulled out farther than normal. Otherwise, the toner cartridge coupler may become dislodged. Remove the front access cover.

  • Page 96

    Position the printer with the left rear corner hanging over the edge of the table. Swing the cover open. Lift the top rear of the cover over the pivot point, and drop the cover away from the printer. Lexmark™ E250d and E250dn...

  • Page 97

    4512-220, -230 Right side cover removal Remove Tray 1. Open the front access cover. Open the rear door. Release the latches (A), and swing the cover open. Position the printer with the right rear corner hanging over the edge of the table. Lift the top rear of the cover over the pivot point, and drop the cover away from the printer.

  • Page 98

    Lift the rear cover, unhooking it from the frame at the bottom, and remove. Note: In re-installation, check to make sure that the fuser ground cable is routed out of the way and is not pinched or damaged. Lexmark™ E250d and E250dn...

  • Page 99

    4512-220, -230 Top cover removal Remove the right side cover. See “Right side cover removal” on page 4-5. Remove the left side cover. See “Left side cover removal” on page 4-4. Open the rear door. Remove the two screws (A) from the two front corners on the top cover, the two screws (B) from the two rear corners on the top cover, and the screw (C) on the left side.

  • Page 100

    Verify the proper alignment of the top cover with the paper exit guide along the mating edges at the rear of the exit tray. • Verify that the rollers in the top cover contact the exit guide rollers at the top rear. There are arrows under the top cover to verify the location of the rollers. Lexmark™ E250d and E250dn...

  • Page 101

    4512-220, -230 Auto comp removal Remove the duplex. See “Duplex removal” on page 4-18. Remove the auto comp clutch. See“Auto comp clutch removal” on page 4-10. Use a spring hook or a small screwdriver to rotate the latch toward the bottom of the printer until it is pointing downward.

  • Page 102

    Remove the screws (A). Note: Resistance to loosening the screw may have to be applied to the shaft. Use a finger or small screwdriver against the coupler behind the clutch. Remove the auto comp clutch. 4-10 Lexmark™ E250d and E250dn...

  • Page 103

    4512-220, -230 Auto comp drive shaft assembly removal Remove the auto comp clutch. See “Auto comp clutch removal” on page 4-10. Use a spring hook or a small screwdriver to dislodge the arm of the shaft bushing, and rotate the arm counterclockwise as far as it will go.

  • Page 104

    Remove the two screws (A). Lift the lower edge of the shield, slide it to the right, and remove. Release the four inner latches (B). Remove the bezel and lens while the door remains open. 4-12 Lexmark™ E250d and E250dn...

  • Page 105

    4512-220, -230 Controller card removal Warning: • Always touch a ground before touching the card. • Handle the card carefully by the edges. • Never replace the operator panel and controller card at the same time without a successful POR in between.

  • Page 106

    Re-installation note: When replacing the controller card, make sure to route all of the cables through the correct shield opening. Make sure that the ground wire that is being held by the front, upper screw is in the correct location before installing. 4-14 Lexmark™ E250d and E250dn...

  • Page 107

    4512-220, -230 Cover open sensor removal Remove Tray 1. Open the front cover. Open the right side cover. See steps 1 and 2 of “Right side cover removal” on page 4-5. Remove the controller card cover. Loosen the one screw (A) from the shield that protects the sensor. Disconnect the cable from J6 on the controller card.

  • Page 108

    Note: Be sure to protect the machine from marring. Remove the six screws (A), the machine screw (B), and the ground cable screw (C). Lift the main motor drive, and disconnect the motor cable (D). 4-16 Lexmark™ E250d and E250dn...

  • Page 109

    4512-220, -230 Remove the coupling spring (E). Remove the developer drive coupling (F). 4-17 Repair information...

  • Page 110

    Remove the screw (C) opposite from screw (B) on the other side of the printer. Note: The ground cable is attached to screw (C). When re-installing, be sure to reconnect the ground cable. Remove the media level indicator. See “Media level indicator removal” on page 4-33. 4-18 Lexmark™ E250d and E250dn...

  • Page 111

    4512-220, -230 Remove the six screws (D). Lift the right side (opposite the coupler) and remove the duplex. Note: At re-installation, before tightening the screws, locate the duplex unit against the left side frame. (Left side relative to the picture above.) 4-19 Repair information...

  • Page 112

    Remove the duplex coupling and gears (A) (the screw and plastic retainer). Remove the duplex coupling (B) and mating link. Note: The link (not shown) that connects the duplex and duplex coupling is part of this FRU as well as the duplex FRU. 4-20 Lexmark™ E250d and E250dn...

  • Page 113

    4512-220, -230 Fan removal Open the right side cover. See steps 2 through 4 of “Right side cover removal” on page 4-5. Remove the two screws (A) holding the fan to the side frame. Unplug the cable from J4 on the controller card. Note: Be sure to remove the toroid before removing the cables.

  • Page 114

    Remove the two screws (A) and the one machine screw (B) that secures the ground cable. Disconnect the thermistor cable above the fuser. Remove the controller card cover. Disconnect the exit sensor cable from J11 on the controller card. Disconnect the fuser power cable above the fuser. 4-22 Lexmark™ E250d and E250dn...

  • Page 115

    4512-220, -230 Unlatch the fuser (see (A) and (B) in the second photo below), and remove. Reinstallation note: • Be sure to reroute the cables back through their retainers. • If the printer has been moved following the removal of the fuser, verify that the cross shaft behind the fuser is in place.

  • Page 116

    Remove the four screws (A), the machine screw (flange head) (B), and the machine screw (button head) (C). Use the hook end of a spring hook to disconnect the fuser power cable from the LVPS/HVPS side. Note: The connector latch (D) is toward the side frame as shown. 4-24 Lexmark™ E250d and E250dn...

  • Page 117

    4512-220, -230 Link developer drive and access door removal Remove the main motor drive. See “Main motor drive removal” on page 4-28. Remove the coupling assembly. See “Developer drive coupling assembly removal” on page 4-16. Disconnect the front access door from its hinges. See “Front access cover removal”...

  • Page 118

    Remove the four screws (A), the machine screw (B) and the machine screw (C). Unhook the red cable (D) located in the left side frame. Lift the metal cover so the connecting cables (E) and (F) can be unplugged on the side shown. 4-26 Lexmark™ E250d and E250dn...

  • Page 119

    4512-220, -230 Rotate the assembly, and unplug the remaining cables. Remove the assembly. Re-installation note: When re-installing the LVPS/HVPS assembly: • Be sure to locate the rear flange of the card bracket inside of the shield prior to rotating the card assembly into final position.

  • Page 120

    IMPORTANT: The ground strap (held by screw B) is not included in the main motor drive FRU. Be sure to remove this strap, and install it in the new drive. Lift the motor end, and disconnect the main motor cable (D). Lift the gear assembly, and remove the developer drive spring (E). 4-28 Lexmark™ E250d and E250dn...

  • Page 121

    4512-220, -230 Rotate the motor drive counterclockwise until the two plastic links can be separated. Remove the main motor drive. 4-29 Repair information...

  • Page 122: Manual Feed Sensor Removal

    • Place the sensor into position, and reconnect the cable on the controller card. • Using the spring hook, be sure to reroute the cable through the three retainers between the sensor and side frame. 4-30 Lexmark™ E250d and E250dn...

  • Page 123

    4512-220, -230 Manual paper feed clutch Open the left side cover. See “Left side cover removal” on page 4-4 for more information. Tilt the printer onto its right side, and remove the six screws (A), the screw (B), and the ground cable screw (C).

  • Page 124

    Remove the main motor drive. See “Main motor drive removal” on page 4-28. Remove the auto comp clutch. See “Auto comp clutch removal” on page 4-10. Remove the three screws (A). Remove the manual feed solenoids. 4-32 Lexmark™ E250d and E250dn...

  • Page 125

    4512-220, -230 Media level indicator removal Remove the left side cover. See “Left side cover removal” on page 4-4. Turn the printer onto its top. (Be careful to protect the covers.) Unhook and remove the spring (A). Unhook the link (B) from the indicator level. 4-33 Repair information...

  • Page 126

    Unsnap the shaft from its pivot, which is attached to the back of the LVPS/HVPS shield (D). Align the link end of the shaft with the opening in the side frame, and remove the shaft and spring anchor (E). 4-34 Lexmark™ E250d and E250dn...

  • Page 127

    4512-220, -230 Narrow media sensor removal Remove the top cover. See “Top cover removal” on page 4-7. Turn the top cover upside down. Remove the ground strap screw (A) and the ground strap. Remove the narrow media sensor. 4-35 Repair information...

  • Page 128

    Warning: Do not replace the operator panel and the controller card at the same time. Each card contains the printer settings. When either of these cards is new, it obtains its settings from the other card. Critical factory settings are lost when both are new and replaced at the same time. 4-36 Lexmark™ E250d and E250dn...

  • Page 129

    4512-220, -230 Paper exit guide assembly removal Remove the rear cover. See “Rear cover removal” on page 4-6. Remove the one screw above the reversing solenoid. See “Top cover removal” on page 4-7. Remove the three screws (A). Lift the back of the top cover (right side in photo) to prevent the gears on the assembly from touching other items while removing, especially the fuser mounting bracket.

  • Page 130

    Notice the direction of the points on the edge. Those points should be directed in the paper feed direction as shown. Make sure the new paper feed rollers are captured between the rims of the plastic hub. If the orientation is questionable, run Print Quality sheets, and check for skew. 4-38 Lexmark™ E250d and E250dn...

  • Page 131

    4512-220, -230 Paper input and duplex sensor removal Remove the duplex unit. See “Duplex removal” on page 4-18. Remove screws (A) holding the two sensors. Remove the sensor assembly. Note: Be sure to secure cables in retainers when installing the new assembly. The solenoid cable should be installed on top of the sensor cables.

  • Page 132

    Be sure to place the toroid back over the cables. • Mechanically adjust the printhead, if necessary. See “Printhead assembly mechanical adjustment” on page 4-13. • Electronically adjust the printhead. This is a necessary step. See “Printhead assembly electronic adjustment” on page 4-8. 4-40 Lexmark™ E250d and E250dn...

  • Page 133

    4512-220, -230 Reversing solenoid removal Remove the top cover. See “Top cover removal” on page 4-7. Remove the controller card shield. (Loosen the four screws, and slide.) See “Right side cover removal” on page 4-5. Disconnect the cable from J9 (DP REV SOL) on the controller card. Remove the two screws (A).

  • Page 134: Transfer Roll Removal

    If the old springs are moved, feel the base of the springs to assure that they are on the posts. The top of the springs must be captured in the bearings of the transfer roll. 4-42 Lexmark™ E250d and E250dn...

  • Page 135

    4512-220, -230 Tray 2 auto comp tire removal Gently pull the rubber tire loose from the wheel, and replace it with a new tire. Note: Look at the nap of the tire, and orient the tire for highest friction when picking the paper. 4-43 Repair information...

  • Page 136: Upper Front Frame Group Removal

    Lift the right side to align the flat on the guide shaft with the opening. Slide the shaft through the opening. Slide the cover to the right to free the left side, and remove the front cover guide. 4-44 Lexmark™ E250d and E250dn...

  • Page 137

    4512-220, -230 Installation note: Move the printer so the front hangs over the front edge of the work surface. Anchor the left spring on its rear post and maintain tension on it while snapping the assembly into position on the left side. Use the spring hook from below the printer to anchor the front of the spring.

  • Page 138

    Use a spring hook to unfasten each of the anchors on the back of each strip. Remove the strip from inside the tray. Wear strip removal (tray 2) Pull up the strip with the spring hook to free it at the top. Lift the strip out. 4-46 Lexmark™ E250d and E250dn...

  • Page 139

    4512-220, -230 Note: When replacing the strip: • Push the strip up with your thumb to make sure that the strip is in place. • Turn the tray over so that you are looking at the bottom of the strip. Using the spring hook, check to make sure that the end of the strip is secure and the strip is fastened tightly.

  • Page 140

    4512-220, -230 4-48 Lexmark™ E250d and E250dn...

  • Page 141: Locations And Connections, Locations, Front View, Rear View

    4512-220, -230 5. Locations and connections Locations Front view Rear view Locations and connections...

  • Page 142: Controller Card Connector Pin Values

    24 V dc Reversing solenoid Less than 1 V dc Less than 5 V dc Narrow media sensor 5 V dc Ground Less than 5 V dc Exit sensor 5 V dc Ground 5 V dc Thermistor Ground Lexmark™ E250d and E250dn...

  • Page 143

    4512-220, -230 Connector Pin # Value Value Comments cableplugged cable unplugged (if different) 5 V dc LSU (HSYNC) 2, 3 Signal Ground Signal 3.2 V dc Main motor Ground 5 V dc 24 V dc Less than 24 V dc Signal LVPS/HVPS Ground...

  • Page 144: Connectors

    4512-220, -230 Connectors System board Connector Pin no. Signal J1 USB Port Ground USB +5 V dc USB D- USB D+ Ground Ground Lexmark™ E250d and E250dn...

  • Page 145: Safety Inspection Guide, Maintenance Kits

    Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Lubrication specifications FRUs are typically lubricated as needed from the factory. If not, lubricate only when parts are replaced or as needed, not on a scheduled basis.

  • Page 146

    4512-220, -230 Lexmark™ E250d and E250dn...

  • Page 147: How To Use This 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. Machine type and model Description 4512-220 Lexmark E250d 4512-230 Lexmark E250dn Parts Catalog...

  • Page 148

    4512-220, -230 Assembly 1: Covers Service Manual...

  • Page 149

    4512-220, -230 Assembly 1: Covers Asm- Part Units/ Units/ Description Index number mach 1–1 40X5069 Top cover assembly (includes narrow media sensor) 40X5068 Top cover right flag 40X2839 Rear upper and lower cover assembly 40X2858 Legal extender dust cover 40X2837 Right side cover 40X2843 Optional media drawer assembly...

  • Page 150

    4512-220, -230 Assembly 2: Electronics Service Manual...

  • Page 151

    4512-220, -230 Assembly 2: Electronics Asm- Part Units/ Units/ Description Index number mach 2—1 40X2804 LSU, E250d/E250dn (printhead) 40X2800 Fuser assembly, 110 V 40X2801 Fuser assembly, 220 V 40X2802 Fuser assembly, 100 V 40X2833 Miscellaneous cable assemblies Thermistor LVPS/HVPS to controller card Main drive gear assembly (motor to controller card) Fuser power (LVPS to fuser) 40X2823...

  • Page 152

    4512-220, -230 Assembly 3: Frame Service Manual...

  • Page 153

    4512-220, -230 Assembly 3: Frame Asm- Part Units/ Units/ Description Index number mach 3—1 40X2834 Media exit guide assembly 40X2822 Transfer roll, bearings, gear, spring (CBM) 40X2858 Legal extender dust cover 40X2850 Screws, miscellaneous TP2NCX3X6PF-Ni TP2C-4.0+8PF-Ni M3.0*0.5+6PF-Ni M3.0*0.5+4PF-Ni M3.5*0.6+6P-Ni 40X2853 ACM drive shaft assembly 40X2841 Complete duplex assembly...

  • Page 154

    4512-220, -230 Assembly 4: Options Asm- Part Units/ Units/ Description Index number mach 40X1364 32MB SDR DIMM 40X1365 64MB SDR DIMM 40X1367 Parallel cable, packaged (3 m) 40X1368 USB cable, packaged (2 m) 40X1513 Simplified Chinese font card assembly 40X1514 Traditional Chinese font card assembly 40X1512 Japanese font card assembly...

  • Page 155

    4512-220, -230 Assembly 5: Power cords Asm- Part Units/ Units/ Description Index number mach 40X0289 Power cord, 1.8M (straight)–USA, Canada 40X0278 Power cord, 6 foot (straight)–Europe and others 40X0288 Power cord, 8 foot (straight)–Argentina 40X0271 Power cord, 8 foot (straight)–United Kingdom 40X0275 Power cord, 6 foot (straight)–Israel 40X0274...

  • Page 156

    4512-220, -230 7-10 Service Manual...

  • Page 157

    4512-220, -230 Index abbreviations Edge to Edge acronyms error messages Auto CR After LF primary light patterns 2-23 Auto LF After CR service error codes 4-38 autocompensator tires user attendance messages ESD-sensitive parts cables 4-24 fuser power cable compatibility parts catalog 4-21 configuration ID removal...

  • Page 158

    4-16 developer drive coupling assembly print media 4-21 print speed 4-22 fuser toner capacity 4-24 fuser power cable 4-26 LVPS/HVPS card assembly 4-37 paper exit guide assembly Lexmark™ E250d and E250dn...

  • Page 159

    4512-220, -230 start 2-37 symptom tables 2-37 POST 2-38 printer test pages Print Quality Pages 4-38 tires, removal tools transfer roll parts catalog 4-42 removal 2-53 service check user attendance messages Index...

  • Page 160

    4512-220, -230 Lexmark™ E250d and E250dn...

  • Page 161: Part Number Index

    4512-220, -230 Part number index Description Page 40X0270 Power cord, 1.77M (straight)–Japan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0271 Power cord, 6 foot–United Kingdom - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0274...

  • Page 162

    4512-220, -230 40X2839 Rear upper and lower cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X2840 Front access cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X2841...

  • Page 164

    Print defects guide Page 1 of 1 Print defects guide Defects often repeat down a page. In such cases, matching the defect frequency to one of the sets of vertical lines below can help identify the particular part that may be causing the defect. For example, the distance between these two marks represents a repeating defect caused by the toner cartridge.

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