E250dx Depot Repair Procedure Creation Date: 09/26/06

TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06

Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Lexmark E250d and E250dn

Printer
Descriptions Marketing Name Model Type
Lexmark E250d 4512-220
Lexmark E250dn 4512-230

Parts Required
Photoconductor Kit
Return Program Toner Cartridge

Tools Required
E250 service manual
Flat-blade screwdrivers of various sizes
Phillips screwdrivers of various sizes
Needlenose pliers
Spring hook
Analog or digital multimeter
Flash light (optional, but strongly recommended)
Diagonal side cutters (optional, but recommended)

Table of
Contents Topic See Page
Printer Condition and Service History 2
External Visual Inspections 5
Internal Visual Inspections 7
Functional Tests 8
Network Card Testing 11
Repair Procedure Completion Checklist 13
QC Checklist 14
Packaging 15
Revisions 15

Page 1 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Printer Condition and Service History

Printer versus If the printer ... Then …

Work Order Information matches the work order Continue
Information does not match the work order Set this printer to the side and notify your supervisor
of the discrepancy

Scrap Scrap the printer if one of the following conditions apply:

Conditions • Frame Damage
• Excessive toner/dust contamination.
• Rodent/insect contamination.

Prepare for Step Action

Testing 1 Open the front cover and verify the presence of the transfer roller.
2 Install a working toner cartridge.
3 Load tray 1 with at least 20 pages of plain letter size paper.
4 Attach a power cord to the printer and a grounded power source.
5 Move the printer’s power switch to the “ON” ( | ) position.

Ready? If the printer displays… Then

An error light. Determine what parts are needed to
resolve the error condition.
A ready light Continue testing.

Update RIP and If the update fails… Then

Engine Code Once Try updating again
with Orion Twice Determine what parts are needed to
resolve the error condition.

Continued on next page

Page 2 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Printer Condition and Service History, Continued

Print the Step Action Image

Quality Pages 1 Access the Diagnostics Menu:
a. Turn the printer off.
b. Open the front cover.
c. Hold down the Cancel button while turning the
printer on.
d. Release the button and close the front cover
when the Error light stays on solid.

2 Press and release the Cancel button and the lights

should go dark, except for the light in the Continue
button.

3 Press and hold the Continue button down until all the
lights flash.
4 The 4 quality test pages will print (the last page should
be blank)

7 Use these pages to isolate print quality problems.

Refer to the Print Quality Service checks starting on
page 2-43 of the E250 service manual for diagnosis if
needed.

Continued on next page

Page 3 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Printer Condition and Service History, Continued

What Parts are If the parts are… Then

Needed? In stock Replace the parts and restart this procedure.
Not in stock Make sure an order for them is placed and set the printer aside “Awaiting Parts ”

Review Repair Use the customer complaint as the primary guide in repairing the printer, but previous repairs and errors
History need to be considered as well:

If the printer has been… and Then

Serviced more than once For the same Use the previous complaint and fix as a guide in the
problem current repair
Serviced more than once For various Use the customer complaint as the primary guide in
problems repairing the printer
Never been s erviced N/A Use the customer complaint as the primary guide in
repairing the printer

Page 4 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

External Visual Inspection

External
Surfaces Step Action Image
1 Clean printers with toner/dust
contamination by removing the top, left
and right covers and use compressed air
and/or a toner vacuum. Caution: Avoid
contaminating the printhead with dust.
2 Check the covers for damage. All covers
must meet the A, B, and C surface
cosmetics requirements.
3 Check the following for damage:
o logo
o molded graphics
o LCD lens
o buttons

4 Check the following on the back of the

printer for damage.
• certification label
• USB port and screw
• Parallel port 2 screws and 2 clips.
• Ethernet port (if present)

Attention: On network models insert a

network cable in the Ethernet port and
make sure the port will hold the cable.

Continued on next page

Page 5 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

External Visual Inspection, Continued

Bottom
Step Action Image
1 Remove the paper tray and clean off any
toner or paper dust.
2 Gently flip the printer over to view the bottom.
3 Make sure the 4 rubber feet are present.

4 Check the Auto-connect for damage.

5 Check the Auto-compensator and Pick Tires

for damage.

6 Check the following duplex components for

damage:
o Guide (green plastic piece)
o Spring
o Flag
o Drive Belt

Page 6 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Internal Visual Inspection

Clean Clean the interior of the printer as needed.

Caution: If canned or compressed air is being used to clean the printer avoid contaminating the
printhead on the underside of the top cover with dust or debris.

Transfer Roller Remove the Transfer Roller:

Step Action
1 Set the spring on the right, off to the side.
2 Check the transfer roller for damage.
3 Clean the area under the transfer roller with a toner vacuum .
4 Re-install the transfer roller, and don’t forget the spring on the right side.

HVPS Contacts Examine the High Volt Power Supply contacts on the right side of the printer:

Step Action Image

1 Press on each of the 6
contacts and make sure that
they spring back to their
original position.

2 Check the contacts for

damage or abnormal bends

Duplex Guide
Step Action Image
1 Check the green duplex guide for
damage
2 Raise the duplex guide and check for
any paper or debris underneath.

Page 7 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Functional Tests

Printing the
Event Log Step Action Image
1 Access the Diagnostics Menu:
a. Turn the printer off.
b. Open the front cover.
c. Hold down the Cancel button while turning the
printer on.
d. Release the button and close the front cover
when the Error light stays on solid.

2 Press and release the Cancel button until the Ready and
Toner Low lights are the only ones illuminated.

3 Hold down the Continue button until all the lights flash.
4 Keep the Event Log pages with the printer and turn the
printer off to exit Diagnostics.

Orion Testing
Step Action
1 Insert a toner cartridge for testing, load the paper tray with plain letter size paper and
attach the printer to power.
2 Listen for any unusual noises coming from the printer, and resolve as needed.
3 ????
4 Review the print samples, and make sure there are no:
• Light or blurred characters
• Toner smudges on the front or back
• Vertical Streaks
• Smears

5 Indicate if the Print Test passed on one of the pages.

6 Keep the printed pages with the printer for QC verification.
7 Wait for the test to complete.
8 Make sure all parts of the test pass.

Communication Print 70 pages from a text file on a PC:

and Paper Feed o Print 60 pages to tray 1.
Testing o Print 10 pages using the manual sheet feed.
o Keep 1 page from each with the printer for QC verification.

Continued on next page

Page 8 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Functional Tests, Continued

Duplex Test
Step Action Image
1 Access the Diagnostics Menu:
e. Turn the printer off.
f. Open the front cover.
g. Hold down the Cancel button while
turning the printer on.
h. Release the button and close the front
cover when the Error light stays on solid.

2 Press and release the Cancel button until the

Toner Low and Continue lights are on.

3 Hold down the Continue button until all the

lights flash.
th
4 Press the Cancel button after the 4 page
exits, to stop the test.
5 Keep one of these pages with the printer for
QC verification, and leave the printer in the
Diagnostics Mode.

Maintenance Use the table below to determine if the maintenance count needs to be reset:
Count
If the page count is and the … Then ...
...
Low Fuser is being Reset the Maintenance Count
replaced
Low Fuser condition is OK Reset the Maintenance Count
60,000 – 80,000 Fuser is being Reset the Maintenance Count
replaced
60,000 – 80,000 Fuser condition is OK Reset the Maintenance Count
High Fuser is being Reset the Maintenance Count
replaced
High Fuser condition is OK Research the printer’s service history:

If the fuser … Then …

Was replaced Reset the Maintenance Count
previously
Was not replaced Replace the fuser and reset
the Maintenance Count

Continued on next page

Page 9 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Functional Tests, Continued

Resetting the
Maintenance Step Action Image
Count 1 Access the Configuration Menu:
i. Turn the printer off.
j. Open the front cover.
k. Hold down the Continue button while
turning the printer on.
l. Release the button and close the front
cover when the Error light stays on solid.

2 Press and release the Cancel button until just

the Toner Low light is on.
3 Hold down the Continue button until all the
lights flash.
4 Turn the printer off and back on to exit the
Configuration menu.

Page 10 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Network Card Testing

Print a Network
Settings Page Step Action Image
1 Press and release the Continue button to print a
menu and network setup page.
2 Verify the following items on the page:
• Status = Not Connected
• Active = Yes
• DHCP,BOOTP,RARP Enabled = Yes, Yes,
Yes
• Address Source = Manual
• Address = 0.0.0.0

Network Card
Testing Step Action Image
1 Attach a network cable to the
printer.
2 A network settings page will print
when an IP address is acquired.
3 Locate the IP address in the
TCP/IP section of the network
settings page.

Attention: an IP address indicates

that the network card is functioning.

4 Keep this page with the printer for

QC verification that the network
card is functional.

Continued on next page

Page 11 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Network Card Testing, Continued

Resetting the
Network Card Step Action Image
1 Access the Diagnostics Menu:
m. Turn the printer off.
n. Open the front cover.
o. Hold down the Cancel button while turning the
printer on.
p. Release the button and close the front cover
when the Error light stays on solid.

2 Press and release the Cancel button until just the Ready
light is flashing.
3 Hold down the Continue button until all the lights flash.

4 The printer will reset and return to a normal operating

mode.
5 Press and release the Continue button to print a menu
and network setup page.
6 On the page that prints verify the following:
o Status = Not Connected
o Active = Yes
o DHCP,BOOTP,RARP Enabled = Yes, Yes, Yes
o Address Source = Manual
o Address = 0.0.0.0

Page 12 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Repair Completion

Checklist
RIP and Engine code have been updated (when necessary)
Print Quality is OK
Covers are OK & clean.
Operator panel is OK
Ports are OK
Bottom OK (4 feet, auto-connect, duplex & auto-comp)
UL label is OK
Inside clean
Transfer roller OK
HVPS contacts are OK
Duplex guide is OK
Printer sounds OK
Orion testing completed successfully
Duplexer is functioning properly
Paper feeds OK
Network card is functioning properly

Page 13 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Quality Control

Checklist
Test pages from the repair process are present.
Verify that the serial number on the paper work matches the printer.
Covers are clean and undamaged
Logo/graphics are OK
Certification label on back is OK
Ports are ok:
o Parallel clips are present.
o Ethernet port will hold a cable.

Inside of printer is clean (no dust or toner)

Transfer roller OK.
6 Hi-volt contacts OK
Print a Menu Settings page and verify the following:
o Serial number on pages matches printer
o Network models, Network settings page printed and the TCP/IP settings have
been reset
Print the Quality pages and verify the following:
o Print quality is acceptable
Clean the printer as needed
Remove and file paperwork
Place the menu settings page (printed above) on top of the printer along with a copy of
the packaging instruction sheet (Document #: ??) before sending the printer to
packaging.

Page 14 of 15
 E250dx Depot Repair Procedure Creation Date: 09/26/06
TLI/ Part Number sequence: xxxxxx Revision Date: 09/26/06
Content Owner: George Maslin Doc ID: USDEPOTDOC62
Process Flow Owner: Andy Steinkuhl

Packaging

pending

Revisions

Revision Date Revision Detail Revised by

09/26/06 Document creation Michael Trinler

Page 15 of 15