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Lexmark X215 MFP Service Manual

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Lexmark X215 MFP
4038-001
• 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.

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Summary of Contents for Lexmark X215 MFP

  • Page 1 Lexmark X215 MFP 4038-001 • 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 Lexmark, and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. All other trademarks are the property of their respective owners.

  • Page 3: Table Of Contents

    4038-001 Table of contents Laser notices ......... . . vii Safety information.
  • Page 4 4038-001 Machine tests ........3-9 DRAM Memory test .
  • Page 5 4038-001 Scanner assembly hinge removal ..... 4-72 System board removal ......4-73 Transfer roll removal .
  • Page 6 4038-001 Service Manual...

  • Page 7: Laser Notices

    4038-001 Laser notices The following laser notice labels may be affixed to this printer as shown. Laser advisory label With the middle cover removed, the laser advisory label is affixed to the top of the printhead. Laser notices...
  • Page 8 4038-001 Class 1 Laser Statement label The Class 1 laser label is located on the rear of the machine. Example: viii Service Manual...

  • Page 9: Laser Notice

    4038-001 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 10 4038-001 Avis relatif à l’utilisation de laser Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.
  • Page 11 4038-001 Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
  • Page 12 4038-001 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.
  • Page 13 4038-001 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 14 4038-001 Laser-melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
  • Page 15 4038-001 Japanese Laser Notice Chinese Laser Notice Laser notices...
  • Page 16 4038-001 Korean Laser Notice Service Manual...

  • Page 17: Safety Information

    4038-001 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 18 4038-001 Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
  • Page 19 4038-001 Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. •...
  • Page 20 4038-001 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 21 4038-001 Safety information...

  • Page 22: Preface

    4038-001 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed, as well as general environmental and safety instructions.

  • Page 23: General Information

    4038-001 1. General information The Lexmark™ X215 MFP is a compact multifunction printer that offers scanning, printing, copying, and faxing. Machine features Print speeds up to 17 ppm resolution Print up to 600 x 600 dpi aper tray capacity up to 250—sheets ront output bin 150—sheet capacity...

  • Page 24: Print Materials

    4038-001 Print materials Always use print materials that meet the guidelines for use with this machine. Using print materials not recommended may cause paper jams or print quality problems. Selecting print materials Input source/capacity Size (mm/in.) Bypass Paper tray feeder Plain paper Yes/250 Yes/1...
  • Page 25 4038-001 Input source/capacity Size (mm/in.) Bypass Paper tray feeder Card stocks No/0 Yes/1 A6 card (105 x 148/4.13 x 5.88) Post Card (101.6 x 152.4/4 x 6) Hagaki (100 x 148/3.94 x 5.83) Maximum capacity may be reduced depending on paper thickness. Media must be fed one sheet at a time through manual bypass.
  • Page 26 4038-001 • Load specialty media one sheet at a time. • Use only materials recommended for use with laser printers. • To prevent specialty media, such as transparencies and label sheets, from sticking together, remove each sheet from the output tray as it is printed. •...

  • Page 27: Cleaning The Machine

    4038-001 Cleaning the machine To maintain print quality, follow these cleaning procedures each time the toner cartridge is replaced or if print quality problems occur. • Do not put water directly onto any part of the machine. • Do not use ammonia-based cleaners or volatile solvents, such as thinner, on the printer.

  • Page 28: Cleaning The Inside Of The Machine

    4038-001 Cleaning the inside of the machine During the printing process, paper, toner, and dust particles can accumulate inside the machine. This buildup can cause print quality problems, such as toner specks or smearing. 1. Turn the machine off, unplug the power cord, and then wait for the machine to cool down.
  • Page 29 4038-001 4. With a dry, lint-free cloth, wipe away any dust and spilled toner from the toner cartridge area and the toner cartridge cavity. Warning: • To prevent damage to the toner cartridge, do not expose it to light for more than a few minutes. Cover it with a piece of paper, if necessary.

  • Page 30: Cleaning The Scan Unit

    4038-001 Cleaning the scan unit Keeping the scan unit clean helps ensure the best possible copies. 1. Slightly dampen a soft, lint-free cloth or paper towel with water. 2. Open the document cover. 3. Wipe the surfaces of the document glass and ADF until they are clean and dry.

  • Page 31: Cleaning The Photoconductor Drum

    4038-001 Cleaning the photoconductor drum If there are streaks or spots on your print, the photoconductor drum may require cleaning. The operator panel menu includes a Clean Drum option that may help to improve the print quality. To clean the photoconductor drum: 1.

  • Page 32: Abbreviations

    4038-001 Abbreviations Automatic document feed Bits per second Charge-coupled device CCITT International consultative committee on telephone and telegraphy Decibel Dots per inch DRAM Dynamic random access memory Electrophotographic process Electrostatic discharge Field replaceable unit HSYNC HVPS High voltage power supply Kbps Kilobits per second Liquid crystal display...

  • Page 33: Diagnostic Information

    4038-001 2. Diagnostic information Start CAUTION: NEVER manually actuate or disable the top cover interlock switch and the printhead shutter actuator at the same time. To perform some of the service checks and tests, such as troubleshooting paper feed problems, you need to actuate the top cover interlock switch with the covers opened or removed and power applied to the machine.

  • Page 34: Error Message Table

    4038-001 Error message table Clearing display messages: Display Meaning Solution Bypass Jam Paper was sensed at • Load paper in the the manual bypass manual bypass or sensor, but not at the remove the jam from main paper feed/toner the manual bypass. cartridge present •...
  • Page 35 4038-001 Display Meaning Solution Document Jam Paper was sensed at • Make sure the ADF the ADF registration scan sensor actuator sensor, but not at the is not broken, ADF scan sensor. improperly installed or stuck with paper debris. • If the paper path and sensor actuator are clear and working properly, replace the...
  • Page 36 4038-001 Display Meaning Solution Problem in the fuser • Make sure CN1 and unit. CN7 on the HVPS/ LVPS are properly connected. • Check CN1 on the HVPS/LVPS for Fuser Error proper voltage. • If the voltage is correct, replace the fuser.
  • Page 37 4038-001 Display Meaning Solution The printer senses that • Make sure the the thermistor isn’t thermistor is properly connected or faulty. connected to CN7 on the HVPS/LVPS. • If the problem persists replace the fuser. Open Heat Error The fuser unit has Replace the fuser.
  • Page 38 4038-001 Display Meaning Solution Paper Jam 0 Paper was sensed at • Go to the paper path the paper tray empty diagram “Printer sensor, but not at the engine paper path/ manual bypass. paper jams” on page 5-15 to see the region where a paper jam may occur.
  • Page 39 4038-001 Display Meaning Solution Paper Jam 1 The fuser exit sensor • Go to the paper path sensed the leading diagram “Printer edge of the page but engine paper path/ never sensed the paper jams” on trailing edge. page 5-15 to see the region where a paper jam may occur.
  • Page 40 4038-001 Display Meaning Solution Paper Jam 2 Paper was sensed at • Go to the paper path the main paper feed/ diagram “Printer toner cartridge present engine paper path/ sensor, but not at the paper jams” on fuser exit sensor. page 5-15 to see the region where a paper...
  • Page 41 4038-001 Display Meaning Solution Time/Date prompt Prompt appears when • Use the numeric the machine is powered keypad to enter the two-digit month and day, and the four- digit year. For example, 01-23- 2003. • Enter the current time. The default clock setting is 12- hour.

  • Page 42: Symptom Table

    4038-001 Symptom table Symptom Reference Paper feed problems “Paper feed problems” on page 2-11. Printing and copying problems “Printing and copying problems” on page 2-13. Scanning problems “Scanning problems” on page 2-18. Faxing problems “Faxing problems” on page 2-19. Print quality problems “Print quality checks”...

  • Page 43: Paper Feed Problems

    4038-001 Paper feed problems Symptom Possible cause and solution Paper jam Clear the paper jam. Paper sticks together • Ensure that there is not too much paper in the paper tray. Depending on the thickness of your paper, the paper tray can hold up to 250—sheets of paper.
  • Page 44 4038-001 Symptom Possible cause and solution Paper does not feed. • Paper is not loaded correctly. Remove paper from the tray and reload it correctly. • There is too much paper loaded. Remove excess paper from the tray. • The paper is too thick. Use only paper that meets specifications.

  • Page 45: Printing And Copying Problems

    Wait until scanning is complete before using the Machine does printer. not print Machine is not selected as Select Lexmark X215 as the default printer. your default printer in Windows. Front or rear covers are not Close the covers. closed.
  • Page 46 If using Windows 98/Me, 1. Click Start Settings the spool setting may be set Printers. incorrectly. 2. Right-click the Lexmark X215 printer icon. 3. Click Properties. 4. From the Details tab, click Spool Settings. 5. Select the spool setting you want.
  • Page 47 4038-001 Problem Possible cause Solution Software program is Try printing a job from malfunctioning. another program. Operating system is • Exit Windows and restart malfunctioning. the computer. • Turn the machine off and then back on again. Illustrations The setting in the software Print the document with print incorrectly program is wrong.
  • Page 48 4038-001 Problem Possible cause Solution Copies are too • If the original is light, light or too dark press Darkness to darken the background of the copies. • If the original is dark, press Darkness to lighten the background of the copies.
  • Page 49 4038-001 Problem Possible cause Solution Frequent jams • Check/adjust paper guides. • Fan the stack of paper, and then turn it over in the paper tray. • Replace paper with a fresh supply. • Ensure the paper is the proper paper weight. 20 lb.

  • Page 50: Scanning Problems

    4038-001 Scanning problems Problem Possible cause and solution Scanner does not work. • Machine may be busy printing. Wait until printing completes before using the scanner. • Make sure the document to be scanned is facedown on the document glass, or faceup in the Automatic Document Feeder.

  • Page 51: Faxing Problems

    4038-001 Faxing problems Problem Possible cause and solution • Unplug the power cord and plug it in again. • Ensure that there is power to the electrical outlet. Machine is not working, no display, and buttons are not working No dial tone •...
  • Page 52 4038-001 Problem Possible cause and solution Incoming fax has blank • Fax machine sending the fax may be faulty. spaces or is received with • Fax machine sending the fax may have a a poor quality dirty document glass. Clean the document glass.

  • Page 53: Print Quality Checks

    4038-001 Print quality checks Problem Possible causes • Straight thin black • The drum inside the toner cartridge has vertical line and band probably been scratched. • Dark black vertical • Toner cartridge failure. bands • Foreign material between transfer/charge/ development rollers.
  • Page 54 4038-001 Problem Possible causes Dark or blurry horizontal • Check the toner cartridge installation. stripes • Toner cartridge may be defective. Toner cartridge failure. AaBbCc • Bad or dirty voltage contacts. AaBbCc AaBbCc AaBbCc AaBbCc Toner smear • Clean inside printer. See “Cleaning the inside of the machine”...
  • Page 55 4038-001 Problem Possible causes Background scatter • Paper may be damp. Try printing with a different batch of paper. Note: Paper does absorb moisture. Open paper packages when ready for use. • If background scatter occurs on an envelope, change printing layout to avoid printing over areas with overlapping seams on the reverse side.
  • Page 56 4038-001 Problem Possible causes Curl or wave • Check paper type and quality. See “Selecting print materials” on page 1-2 for more information. Note: High temperature and humidity can cause paper curl. • Turn over the stack of paper and rotate 180°...
  • Page 57 4038-001 Problem Possible causes Black or dark image • Check that toner cartridge is installed properly. • Toner cartridge failure. • Bad or dirty high voltage contacts. • HVPS failure. Loose toner • Clean the inside of the printer. See “Cleaning the inside of the machine”...
  • Page 58 4038-001 Problem Possible causes • Background appears in • Check for recommended paper weight print area (recycled or poor quality paper). See “Selecting print materials” on page 1-2 • Gray background for more information. AaBbCc • Check machine environment. AaBbCc •...
  • Page 59 4038-001 Problem Possible causes Residual image occurs in • Toner cartridge failure. the black image printing at • Bad or dirty high voltage contacts. 37 mm intervals AaBbCc AaBbCc AaBbCc AaBbCc AaBbCc AaBbCc Residual image occurs at • Fuser temperature maintained too high. 64 mm intervals Check for toner buildup on hot roller and thermistor surface.
  • Page 60 4038-001 Problem Possible causes Blank page prints • Redistribute the toner. • If necessary, replace the toner cartridge. • Ensure the printed file doesn’t have blank pages. • Bad or dirty high voltage contacts; inspect and clean contacts. • Replace the LVPS/HVPS. •...
  • Page 61 4038-001 If an abnormal image prints periodically, check the following parts: Fuser Toner Cartridge Distance Related Type of between printer abnormal Replace repeated components image marks 75.5 mm OPC drum White or black Toner cartridge spots/voids 37.7 mm Charge roller Black spots Toner cartridge 37.0 mm...

  • Page 62: Service Checks

    4038-001 Service checks Cooling fan Action • Perform the “Motor, Fan, Solenoid test” on page 3-11 see if the fan turns on. • If the fan turns on, the problem is likely associated with the system board. Cooling fan, • If the fan does not turn on, make LVPS/HVPS, sure the cooling fan cable is system board...
  • Page 63 4038-001 Main drive motor Action • Perform the “Motor, Fan, Solenoid test” on page 3-11 see if the main drive motor turns • If the motor works but is noisy, replace the main drive assembly. Main drive motor, • If the motor works correctly in this system board, test but not during normal printing, LVPS/HVPS...
  • Page 64 4038-001 Dead machine Action Line voltage Check the AC line voltage to make sure it is correct. LVPS/HVPS to system Ensure the cable connecting the board cable LVPS/HVPS to the system board is properly seated. LVPS/HVPS Check the following voltages on CN2 of the LVPS/HVPS: •...
  • Page 65 4038-001 Operator panel, scanner card assembly Action Operator panel • Perform the “Operator Panel scanner card assembly test” on page 3-13 to check for proper operation of the LCD screen, LED(s) and key buttons. • If the operator panel does not work at all, check the following on the scanner card: —...
  • Page 66 4038-001 2-34 Service Manual...

  • Page 67: Diagnostic Aids

    4038-001 3. Diagnostic aids Configuration modes Clear All Memory mode The Clear All Memory setting is used to reset all settings back to factory defaults. Note: Page counts are not reset when Clear All Memory is performed. To adjust Clear All Memory: 1.

  • Page 68: Clear Count Mode

    4038-001 Clear Count mode The Clear Count mode is used to reset the various page counters / cartridge counters stored in printer NVRAM. To adjust Clear Counts: 1. Press Menu, #, 1, 9, 3, 4. The LCD displays TECH. 2. Press Menu, and then Select. 3.

  • Page 69: Dial Mode

    4038-001 Dial mode The Dial mode setting allows the modem card to be changed between pulse or tone dial modes. To adjust Dial mode: 1. Press Menu, #, 1, 9, 3, 4. The LCD displays TECH. 2. Press Menu, and then Select. 3.

  • Page 70: Modem Speed Mode

    4038-001 Modem Speed mode The Modem Speed setting is used to select the modem speed. The possible choices are: • • • 12.0 • 14.4 • 28.8 • 33.6 Kbps. To adjust the Modem Speed: Menu, #, 1, 9, 3, 4 1.

  • Page 71: Park Ccd Module Mode

    4038-001 Park CCD module mode This function parks the CCD module in the middle of the flatbed to prevent damage to the CCD module during shipping. Perform this function whenever the printer is to be shipped. To park the CCD module: 1.

  • Page 72: Print Properties Mode

    4038-001 Print Properties mode Settings to adjust for a print job include: • Orientation - the direction information is printed on a page. • 2-UP or 4-UP - multiple pages printed on one sheet. • Scale - the size information is printed on a page. •...
  • Page 73 4038-001 Print settings description From this tab: Change these settings: Layout Orientation - select how the document is oriented on the printed page. Layout - select the type of layout for the document. Paper Copies - select the number of copies to print. Type - select the type of paper to use.

  • Page 74: Send Level Mode

    4038-001 Send Level mode The Send Level setting adjusts the transmission signal level of the modem card. Typically, this level should be under 12dB. Note: The Send Level is set at the factory at an optimal setting. Do not arbitrarily adjust. To adjust Send Level: 1.

  • Page 75: Machine Tests

    4038-001 Machine tests DRAM Memory test The DRAM Memory test checks all DRAM memory on the system board. To enter the DRAM Memory test: 1. Press Menu, #, 1, 9, 3, 4. The LCD screen displays TECH. 2. Press Menu, and then Select. 3.

  • Page 76: Modem Protocol Log Test

    4038-001 Modem Protocol Log test The Modem Protocol log prints the sequence of the CCITT group 3 T.30 protocol during the most recent sending or receiving operation. This report is used to check for send and receive errors. To perform the Modem Protocol log: 1.

  • Page 77: Motor, Fan, Solenoid Test

    4038-001 Motor, Fan, Solenoid test This test checks the following components: • Main drive motor • Paper tray pick—up solenoid • Cooling fan • Main feed roller/bypass solenoid • Pre—transfer LED To enter the Motor, Fan, Solenoid test: 1. Press Menu, #, 1, 9, 3, 1. 2.

  • Page 78: Operator Panel Button Test

    4038-001 Operator Panel Button test The Operator Panel Button test checks all key buttons on the operator panel. To enter the Operator Panel Button test: 1. Press Menu, #, 1, 9, 3, 4. The LCD screen displays TECH. 2. Press Menu, and then Select. 3.

  • Page 79: Operator Panel Test

    4038-001 Operator Panel test To perform the Operator Panel test: 1. Press Menu, #, 1, 9, 3, 8. 2. Press, Select 3. Select LCD LED Key. 4. Press any key to begin the LCD test. — Each pel of the LCD panel is illuminated, starting from left to right.

  • Page 80: Printhead Test

    4038-001 Printhead test The Printhead test checks the following components: • Printhead motor • Printhead HSYNC • Laser diode To enter the Printhead test: 1. Press Menu, #, 1, 9, 3, 1. 2. Select Diagnostic. 3. Press Menu, and then select LSU test. 4.

  • Page 81: Print Quality Pages Test

    4038-001 Print Quality Pages test This function prints a variety of test pages used to verify print quality. There are seven different test patterns. Pattern Description Graphics / image quality Graphics / image quality Horizontal lines White page Dot array (fine) Dot array (coarse) Vertical lines To perform the Print Quality Pages test:...

  • Page 82: Rom Memory Test

    4038-001 ROM Memory test The ROM Memory test checks the ROM memory in the printer. To enter the ROM Memory test: 1. Press Menu, #, 1, 9, 3, 4. The LCD screen displays TECH. 2. Press Menu, and then Select. 3.

  • Page 83: Scanner Ccd Module And Motor Test

    4038-001 Scanner CCD Module and Motor test This test is used to check for proper movement of the CCD module from one side of the flatbed scanner to the other. To perform the scanner CCD tests: 1. Press Menu, #, 1, 9, 3, 8. 2.
  • Page 84 With the cartridge installed, an Off message is posted. This sensor detects both paper jams and cartridge present. Note: There are two tests on the Lexmark X215 MFP LCD that are not used in servicing this printer. — Heat test —...

  • Page 85: Customizing Settings

    4038-001 Customizing settings All the copy options (content, darkness, number, scale, and advanced) using the operator panel buttons can be temporarily modified. Settings remain in effect until a predefined time-out period is expired. Note: • Make all of your selections before pressing Start. •...

  • Page 86: Darkness

    4038-001 Darkness The darkness setting is used for an original document containing paint markings or dark images: • Light - works well with dark print. • Normal - works well with standard typed or printed documents. • Dark - works well with light print or faint pencil markings. To adjust the darkness, press Darkness repeatedly.

  • Page 87: Scale

    4038-001 Scale Original documents copied from the document glass, can be reduced or enlarged from 25% to 400%. Original documents copied from the ADF, can be reduced or enlarged from 25% to 100%. To scale a document to a pre—defined copy size: 1.

  • Page 88: Advanced

    4038-001 Advanced The advanced option, copies images onto a page in a variety of layouts. The advanced settings available when a document is loaded in the ADF include: • Off - turns off the advanced copy features. • Collation - controls the sequence in which multiple page documents are printed.

  • Page 89: Repair Information

    4038-001 4. Repair information 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.
  • Page 90 4038-001 3. Press in on one side of the access cover to release it. 4. Release the other side of the access cover and remove. Service Manual...
  • Page 91 4038-001 Middle cover removal 1. Remove the scanner and scanner card assembly. See “Scanner assembly removal” on page 4-64, and “Scanner card assembly removal” on page 4-68 for more information. 2. Slip the cables out of the middle cover (A) (scanner to system board).
  • Page 92 4038-001 4. From the front of the printer, pull both the middle cover legs away from the printer to release tabs. 5. Lift up to remove the middle cover. Service Manual...
  • Page 93 4038-001 Rear cover removal 1.Remove four screws (A). Repair information...
  • Page 94 4038-001 2. Pull the rear cover to remove. Service Manual...
  • Page 95 4038-001 Scanner assembly document cover removal 1. Remove the left side cover. See “Left side” on page 4-12 more information. 2. Remove the ground screw on the drive assembly. See “Scanner assembly removal” on page 4-64 for more information. 3. Disconnect the scanner assembly cable (A) (CN3). Repair information...
  • Page 96 4038-001 4. Un—thread the cable (A) from the scanner document cover. Service Manual...
  • Page 97 4038-001 5. Open the document cover. Repair information...
  • Page 98 4038-001 6. Lift the document cover until the hinges catch (A). 4-10 Service Manual...
  • Page 99 4038-001 7. Tilt back and lift off the scanner document cover. 4-11 Repair information...
  • Page 100 4038-001 Side cover removals Left side 1. Remove the rear cover. See “Rear cover removal” on page 4-5 for more information. 2. Disconnect the speaker cable (A). 4-12 Service Manual...
  • Page 101 4038-001 3. Slide the cover toward the rear of the printer to release. 4-13 Repair information...
  • Page 102 4038-001 4. Tilt away from printer. 5. Lift to remove the left side cover. 4-14 Service Manual...
  • Page 103 4038-001 Right side 1. Remove the rear cover. See “Rear cover removal” on page 4-5 for more information. 2. Slide the cover toward the rear of the printer to release. 4-15 Repair information...
  • Page 104 4038-001 3. Tilt away from printer. 4. Lift to remove the right side cover. 4-16 Service Manual...

  • Page 105: Automatic Document Feed (Adf) Removals

    4038-001 Automatic document feed (ADF) removals ADF Pick roller 1. Open ADF access cover. 2. Rotate the pick roller bearing (A) to release from the ADF housing. 4-17 Repair information...
  • Page 106 4038-001 3. Lift the pick roller and slide out. ADF Pad 1. Remove the ADF pick roller. See “Automatic document feed (ADF) removals” on page 4-17 for more information. 2. Grab both sides of the ADF pad and lift. 4-18 Service Manual...

  • Page 107: Ccd Module Assembly Removal

    4038-001 CCD module assembly removal 1. Remove the scanner assembly and operator panel. See “Scanner assembly removal” on page 4-64, and “Operator panel removal” on page 4-50 for more information. 2. Remove four screws (A). 3. Slip a flat blade screwdriver under one side then the other to release the tabs.
  • Page 108 4038-001 4. Lift off glass housing to remove. 4-20 Service Manual...
  • Page 109 4038-001 5. Use a flat blade screwdriver to gently pry open the CCD module assembly housing to release the belt. 4-21 Repair information...
  • Page 110 4038-001 6. Pry the shaft loose on both ends and slide out. 4-22 Service Manual...
  • Page 111 4038-001 7. Release the ribbon cable from slots (A). 4-23 Repair information...
  • Page 112 4038-001 8. Disconnect the ribbon cable (A) from the CCD. 9. Remove the CCD assembly. 4-24 Service Manual...

  • Page 113: Card Cage Removal

    4038-001 Card cage removal 1. Remove the left, right and rear covers. See “Left side” on page 4-12, “Right side” on page 4-15, and “Rear cover removal” on page 4-5 for more information. 2. Remove two screws (A) at the rear of the printer. 3.
  • Page 114 4038-001 4. Remove 10 screws (A) in card cage. 4-26 Service Manual...
  • Page 115 4038-001 Note: Hold the card cage as you remove the last screw; as the cage can fall. 4-27 Repair information...
  • Page 116 4038-001 5. Lift the card cage to remove. 4-28 Service Manual...
  • Page 117 4038-001 6. Disconnect all cables on the system board. See reinstallation note. 4-29 Repair information...
  • Page 118 4038-001 Reinstallation note: Make note of the cable locations (A) for the cartridge fuse (CN4) and main paper feed cable (CN6) as these pin connectors can be interchanged. This reversal could cause the printer to malfunction. 4-30 Service Manual...

  • Page 119: Fan Removal

    4038-001 Fan removal 1. Remove the right side cover. See “Right side” on page 4-15 for more information. 2. Disconnect the fan cable from the LVPS/HVPS. 3. Pull the fan straight out to remove. 4-31 Repair information...

  • Page 120: Fuser Removal

    4038-001 Fuser removal 1. Remove the card cage. See “Card cage removal” on page 4-25 for more information. 2. Remove four screws (A). 3. Pull the fuser straight out to remove. 4-32 Service Manual...

  • Page 121: Hvps Contact Removal

    4038-001 HVPS contact removal 1. Remove the right side cover. See “Right side” on page 4-15 for more information. 2. Remove the screw in the cover to the HVPS contacts. 3. Remove the cover. 4. Using needle nose pliers, remove the HVPS contact(s). 4-33 Repair information...

  • Page 122: Lvps / Hvps Card Removal

    4038-001 LVPS / HVPS card removal 1. Remove the card cage. See “Card cage removal” on page 4-25 for more information. 2. Disconnect the cable (CN2) on the LVPS/HVPS card. 4-34 Service Manual...
  • Page 123 4038-001 3. Remove seven screws (A). Note: The bracket securing the LVPS/HVPS card must be removed to reveal the last screw holding the LVPS/HVPS card. 4-35 Repair information...
  • Page 124 4038-001 4. Remove the LVPS/HVPS card. 4-36 Service Manual...

  • Page 125: Main Drive Assembly Removal

    4038-001 Main drive assembly removal 1. With the left side cover removed. See “Left side” on page 4-12 for more information. 2. Remove six screws (A) across the top and bottom of the main drive assembly. 4-37 Repair information...
  • Page 126 4038-001 3. Pull the main drive assembly out a little and disconnect the drive motor cable (A). 4. Lift out the main drive assembly to remove. 4-38 Service Manual...

  • Page 127: Main Paper Feed Roller Removal

    4038-001 Main paper feed roller removal 1. Remove the middle cover and main drive assemblies. See “Middle cover removal” on page 4-3 “Main drive assembly removal” on page 4-37 for information. 2. Remove the three screws (A) and the gear plate. 3.
  • Page 128 4038-001 4. Remove the two screws (A). 5. Lift the metal plate and remove. 4-40 Service Manual...
  • Page 129 4038-001 6. Lift the metal shaft (registration roller) with both bearings attached. Reinstallation note: When installing the four gears, make sure the arms of the solenoids are in the correct position. 7. Pry up the main paper feed roller and remove. 4-41 Repair information...

  • Page 130: Main Feed Roller Solenoid Removal

    4038-001 Main feed roller solenoid removal 1. With the card cage and main drive assembly removed. See “Card cage removal” on page 4-25 “Main drive assembly removal” on page 4-37 for more information. 2. Remove the gear plate (A). 4-42 Service Manual...
  • Page 131 4038-001 3. Remove the pick roller gear. 4. Remove one screw. 4-43 Repair information...
  • Page 132 4038-001 5. Remove the main feed roller solenoid. 4-44 Service Manual...

  • Page 133: Manual Paper Feed Sensor Actuator Removal

    4038-001 Manual paper feed sensor actuator removal 1. With the paper tray feed roller removed. See “Paper tray feed roller removal” on page 4-56 for more information. 2. Flex the tab with your thumb and pry up the end of the actuator. 4-45 Repair information...
  • Page 134 4038-001 3. Lift and remove from the printer. Note: Ensure the spring remains on the actuator. Reinstallation note: Verify the spring is in the correct orientation and flexes the actuator. 4-46 Service Manual...

  • Page 135: Modem Card Removal

    4038-001 Modem card removal 1. With the card cage removed. See “Card cage removal” on page 4-25 for more information. 2. Disconnect the modem ribbon cable (CN3). 4-47 Repair information...
  • Page 136 4038-001 3. Remove two screws (A). 4. Using needle nose pliers, squeeze the standoff to release the modem card. 4-48 Service Manual...
  • Page 137 4038-001 5. Remove the modem card. 4-49 Repair information...

  • Page 138: Operator Panel Removal

    4038-001 Operator panel removal 1. Remove three screws (A) on the underside of the operator panel. 2. Rotate the top portion of the operator panel up. 4-50 Service Manual...
  • Page 139 4038-001 3. Disconnect the operator panel cables (CN1 and CN2). 4. Remove the operator panel. 4-51 Repair information...

  • Page 140: Paper Empty Sensor Actuator Removal

    4038-001 Paper empty sensor actuator removal 1. Remove the card cage. See “Card cage removal” on page 4-25 for more information. 2. Deflect the tab to the side of the actuator to release. 4-52 Service Manual...
  • Page 141 4038-001 3. Remove the paper empty sensor actuator. 4-53 Repair information...

  • Page 142: Paper Feed Sensor Actuator Removal

    4038-001 Paper feed sensor actuator removal 1. Remove the paper tray pick roller assembly and paper empty sensor actuator. See “Paper tray pick roller assembly removal” on page 4-57 “Paper empty sensor actuator removal” on page 4-52 for more information. 2.
  • Page 143 4038-001 3. Lift and remove the paper feed sensor actuator. 4-55 Repair information...

  • Page 144: Paper Tray Feed Roller Removal

    4038-001 Paper tray feed roller removal 1. Remove the paper tray pick roller. See “Paper tray pick roller assembly removal” on page 4-57 for more information. 2. Pull down to release from bushings (A). 3. Remove the paper tray feed roller. 4-56 Service Manual...

  • Page 145: Paper Tray Pick Roller Assembly Removal

    4038-001 Paper tray pick roller assembly removal 1. Remove the main drive assembly. See “Main drive assembly removal” on page 4-37 for more information. 2. Remove the paper tray. 3. Remove the three screws (A) securing the gear plate and remove the plate.
  • Page 146 4038-001 4. Remove the pick roller gear. 5. With the card cage removed. See “Card cage removal” on page 4-25 for more information. 4-58 Service Manual...
  • Page 147 4038-001 6. With a flat blade screwdriver, lift the tab (A) on the right bushing. 4-59 Repair information...
  • Page 148 4038-001 7. While holding the tab up, push the pick roller to the right until the shaft (A) is released on the left side. 8. Remove the pick roller. 4-60 Service Manual...

  • Page 149: Paper Tray Solenoid Removal

    4038-001 Paper tray solenoid removal 1. Remove the card cage and main drive assembly. See “Card cage removal” on page 4-25 “Main drive assembly removal” on page 4-37 for more information. 2. Remove the screw from the solenoid. 4-61 Repair information...
  • Page 150 4038-001 3. Remove the paper tray solenoid. 4-62 Service Manual...

  • Page 151: Printhead Removal

    4038-001 Printhead removal 1. Remove the middle cover. See “Middle cover removal” on page 4-3 for more information. 2. Remove four screws (A) from the printhead. 3. Lift the printhead. 4. Disconnect two connectors. 5. Remove the printhead. 4-63 Repair information...

  • Page 152: Scanner Assembly Removal

    4038-001 Scanner assembly removal 1. Remove the left, right and rear covers. See “Left side” on page 4-12, “Right side” on page 4-15, and “Rear cover removal” on page 4-5 for more information. 2. Remove the ground screw from the main drive assembly. 3.
  • Page 153 4038-001 • cable (A) (CN3) • cable (A) with toroid (CN6) 4-65 Repair information...
  • Page 154 4038-001 • cable (A) (CN2) 4-66 Service Manual...
  • Page 155 4038-001 • ribbon cable (A) (CN1) 4. Remove two screws in rear of printer. 4-67 Repair information...

  • Page 156: Scanner Card Assembly Removal

    4038-001 5. Remove the scanner assembly. Scanner card assembly removal 1. Remove the left side cover. See “Left side” on page 4-12 more information. 2. Disconnect all cables from the scanner card. 4-68 Service Manual...
  • Page 157 4038-001 3. Remove two screws (A) from the card. 4-69 Repair information...
  • Page 158 4038-001 4. Lift out the scanner card to remove. 4-70 Service Manual...

  • Page 159: Scanner Assembly Cushion Removal

    4038-001 Scanner assembly cushion removal Pull the scanner cushion away to release from adhesive. 4-71 Repair information...

  • Page 160: Scanner Assembly Hinge Removal

    4038-001 Scanner assembly hinge removal 1. With the scanner document cover removed. See “Scanner assembly document cover removal” on page 4-7 for more information. 2. Lay the scanner document cover upside down. 3. Remove three screws (A) from the hinge. 4.

  • Page 161: System Board Removal

    4038-001 System board removal 1. Remove the modem card. See “Modem card removal” on page 4-47 for more information. 2. Disconnect the LVPS/HVPS cable (CN14). 3. Remove the modem card ribbon cable (CN1). 4-73 Repair information...
  • Page 162 4038-001 Note: See reinstallation note. 4. Remove five screws (A). 4-74 Service Manual...
  • Page 163 4038-001 5. Remove the system board. 6. Remove the modem card standoff from the system board. Reinstallation note: Reinstall the modem card standoff and ribbon cable on the new system board. 4-75 Repair information...

  • Page 164: Transfer Roll Removal

    4038-001 Transfer roll removal 1. Open the cartridge access cover. 2. Remove the toner cartridge. Note: Place toner cartridge on a flat surface and cover with paper to prevent light getting to the developer. Prolonged exposure of light to the green PC drum can damage the cartridge.
  • Page 165 4038-001 4. Using a pair of needle nose pliers, grab the right end of the shaft and move to the right. Note: Touching the roller may cause print quality problems. 5. Once the left side of the transfer roll is released, still holding with pliers, remove from the printer.
  • Page 166 4038-001 4-78 Service Manual...

  • Page 167: Locations

    4038-001 5. Locations Front view Automatic Document Document guide feeder (ADF) ADF release knob Document input tray Operator panel Scanning Document output tray Front output tray Document cover Front cover Paper tray Paper output Manual extension bypass Locations...

  • Page 168: Rear View

    4038-001 Rear view Telephone line connector Rear cover Power switch USB connector AC power Parallel connector cord connector Service Manual...

  • Page 169: Ep Rollers

    4038-001 EP rollers Fuser Toner Cartridge OPC drum Charge roller Supply roller Developing roller Transfer roller Heat roller Pressure roller Locations...

  • Page 170: Operator Panel

    4038-001 Operator panel Service Manual...
  • Page 171 4038-001 Content Selects the output type for the current copy job. Select from Text, Mixed, or Photo quality. Darkness Adjusts the brightness of the current copy job to the selected value. Number Selects the number of copies that you want to make. Scale Adjusts the size of content on the page.

  • Page 172: Hvps / Lvps Card

    4038-001 HVPS / LVPS card OP101 Switch OP103 OP104 OP102 Service Manual...
  • Page 173 4038-001 Name on Function name # of pins Pin # Signal card Fuser 110 / 220 / 240 V ac Neutral System board 3, 4 +5 V dc +12 V dc +24 V dc 5,6,8,9,10, Ground Cooling fan +24 V dc Cover open C/O Switch switch...

  • Page 174: Modem Card

    4038-001 Modem card Name on Function name # of pins Pin # Signal card System board +5 V dc 2, 12 Ground Service Manual...

  • Page 175: Operator Panel Card

    4038-001 Operator panel card Name on Function name # of pins Pin # Signal card Document cover +5 V dc sensor Ground Scanner card +5 V dc Ground Locations...

  • Page 176: Scanner Card

    4038-001 Scanner card 5-10 Service Manual...
  • Page 177 4038-001 Name on Function name # of pins Pin # Signal card CCD module +5 V dc +24 V dc 1,3,5,7,12, Ground 20,24 Operator panel +5 V dc Ground +5 V dc +24 V dc 1,11,13,15 Ground System board 1,2,3 +5 V dc 8,9,10,18, Ground...

  • Page 178: System Board

    4038-001 System board CN12 CN14 CN10 CN13 C156 CN20 5-12 Service Manual...
  • Page 179 4038-001 Name on Function name # of pins Pin # Signal card HVPS/LVPS +5 V dc +12 V dc +24 V dc 5,6,8,9,10, Ground Paper tray +24 V dc solenoid Pre-transfer +3.3 V dc Toner cartridge fuse Main drive motor Main paper feed +24 V dc / bypass...

  • Page 180: Adf Paper Path

    4038-001 Name on Function name # of pins Pin # Signal card Not used CN13 Modem card CN14 +5 V dc 2,12 Ground ADF paper path ADF-Idle roller ADF roller Pickup roller Document sensor Exit roller Registration sensor Scan sensor Feed roller White-sheet CCD-Module...

  • Page 181: Printer Engine Paper Path/Paper Jams

    4038-001 Printer engine paper path/paper jams Main paper feed/toner cartridge present sensor Paper jam 1 Bypass jam Printhead Fuser Fuser exit sensor Empty sensor Manual bypass sensor Paper jam 2 Paper jam 0 5-15 Locations...
  • Page 182 4038-001 5-16 Service Manual...

  • Page 183: Preventive Maintenance

    4038-001 6. Preventive maintenance The Lexmark X215 MFP does not require preventive maintenance. Preventive maintenance...
  • Page 184 4038-001 Service Manual...

  • Page 185: Parts Catalog

    4038-001 7. Parts catalog How to use this parts catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 186: Assembly 1: Scanner Assembly

    4038-001 Assembly 1: Scanner assembly Service Manual...
  • Page 187 4038-001 Assembly 1: Scanner assembly Index Units Description 1–1 56P1931 Cover asm, ADF access 56P1923 Kit asm, ADF pick roll/pad 56P1922 Roller, ADF idler 56P1983 Scanner, complete 56P1936 Overlay, main 56P1935 Overlay, menu/select/return 56P1934 Panel asm, operator 56P1932 Cushion, document cover 56P1933 Hinge, document cover 56P1941...

  • Page 188: Assembly 2: Main Assembly

    4038-001 Assembly 2: Main assembly Service Manual...
  • Page 189 4038-001 Assembly 2: Main assembly Index Units Description 2—1 56P1914 Cover asm, rear 56P1902 Printhead, complete 56P1916 Cable, main drive motor 56P1915 Fan, cooling 56P1913 Cover, right 56P1904 Card asm, LVPS/HVPS - 110 V 56P1905 Card asm, LVPS/HVPS - 220 V 56P2028 Card asm, LVPS/HVPS - 240 V 56P1906...

  • Page 190: Assembly 3: Frame Assembly

    4038-001 Assembly 3: Frame assembly Service Manual...
  • Page 191 4038-001 Assembly 3: Frame assembly Index Units Description 3—1 56P1963 LED, pre-transfer 56P1965 Bearing, left transfer roller 56P1966 Spring, transfer roll bearing 56P1917 Roller asm, transfer 56P1967 Bearing, right transfer roller 56P1964 Lens, pre-transfer LED 56P1979 Fuser, complete, 110 V 56P1980 Fuser, complete, 220 V 56P1990...
  • Page 192 4038-001 Assembly 3 (cont.): Frame assembly Service Manual...
  • Page 193 4038-001 Assembly 3 (cont.): Frame assembly Index Units Description 56P1975 Clutch asm, main paper feed 1339526 Line cord, US, Canada, Mexico, Costa Rica, Guatemala, Panama, Puerto Rico, Honduras, Nicaragua, El Salvador, Dominican Republic 1339527 Line cord, Australia, New Zealand 1339528 Line cord, Hong Kong, Malaysia, Singapore, Ireland, UK 1339529...
  • Page 194 4038-001 7-10 Service Manual...

  • Page 195: Index

    4038-001 Index clean abbreviations 1-10 abnormal image prints 2-29 envelopes back side contamination 2-29 error message black spots 2-29 bypass jam horizontal shock lines 2-29 door open white or black spots/voids 2-29 fuser error Adobe Illustrator illustrations print incorrectly 2-15 load bypass LSU error memory full...

  • Page 196: Part Number Index

    4038-001 copies too dark 2-16 copies too light 2-16 labels copy image skewed 2-16 Laser notices 1-vii envelopes skew 2-12 class 1 label 1-viii frequent jams 2-17 laser notices half of page is blank 2-14 advisory label 1-vii illustrations print incorrectly 2-15 locations image rubs off easily...
  • Page 197 4038-001 blank page prints 2-28 paper empty sensor actuator 4-52 blurry horizontal stripes 2-22 paper feed sensor actuator 4-54 character voids 2-25 paper tray feed roller 4-56 curl or wave 2-24 paper tray pick roller asm 4-57 dark horizontal stripes 2-22 paper tray solenoid 4-61...
  • Page 198 4038-001 Index-4 Service Manual...
  • Page 199 4038-001 Part number index Description Page ....... . 7-9 1339526 Line cord .
  • Page 200 4038-001 ..... . 7-3 56P1933 Hinge, document cover ......7-3 56P1934 Panel asm, operator .
  • Page 201 4038-001 ..... . 7-7 56P1980 Fuser, complete, 220 V ......7-3 56P1983 Scanner, complete .
  • Page 202 4038-001 Part number index-8 Service...

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