Lexmark Optra C Service Manual
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Lexmark Optra C Service Manual

Lexmark Optra C Service Manual

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Lexmark Optra™ C
5045-001
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Manuals Menu
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 Optra C

  • Page 1 Lexmark Optra™ C 5045-001 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Comments may be addressed to Lexmark International, Inc., Department D22A/035-3, 740 New Circle Road, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

  • Page 3: Table Of Contents

    5045-001 Contents Preface ..........x Notices and Safety Information .
  • Page 4 5045-001 Service Checks (continued) Error (146) Printer Communication Failure ..2-27 Error (147) Engine Board IC Failure ....2-27 Error (148) Developer Unit Rotation Failure .
  • Page 5 5045-001 Print Quality ........2-50 Print Quality Start Of Call .
  • Page 6 5045-001 Diagnostics Mode Tests (continued) LCD Test ........3-7 Memory Tests .
  • Page 7 5045-001 Removal Procedures (continued) Fuser Thermo Switch ......4-32 Fuser Cleaner Assembly ......4-33 Fuser Oil Apply Assembly .
  • Page 8 5045-001 Locations ......... . . 5-1 Switches .
  • Page 9 5045-001 Parts Catalog (continued) Rotary Manual Feed......7-30 Printer Drive ........7-32 Transfer Drum Cleaning Drive .

  • Page 10: Preface

    5045-001 Preface This manual is divided into the following chapters: • “General Information” contains a general description of the printer and the maintenance approach used to repair it. Special tools, test equipment, and options are listed. • “Diagnostic Information” contains error code table, symptom table, and service checks used to isolate failing field replaceable units (FRUs).

  • Page 11: Notices And Safety Information

    5045-001 Notices and Safety Information References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, pro- gram, or service may be used.
  • Page 12 5045-001 Laser Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 825 gemäß...
  • Page 13 5045-001 Avvertenze sui prodotti laser Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 825.
  • Page 14 5045-001 Declaração sobre Laser A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 825.
  • Page 15 5045-001 Lasermeddelelse Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 825. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
  • Page 16 5045-001 Laser-notis Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 825. Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på...
  • Page 17 5045-001 Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 825.
  • Page 18 5045-001 Chinese Laser Notice Korean Laser Notice xviii...

  • Page 19: Trademarks

    5045-001 Trademarks Optra and Lexmark are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. AppleTalk and LocalTalk are trademarks of Apple Computer, Inc., registered in the United States and other countries. PCL ® is a registered trademark of the Hewlett-Packard Company.
  • Page 20 5045-001 Other trademarks are the property of their respective owners.
  • Page 21 5045-001 Notices and Safety Information xxi...

  • Page 22: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
  • Page 23 Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori.
  • Page 24 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. •...
  • Page 25 Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. • La informació pel manteniment d’aquest producte està...
  • Page 26 5045-001 xxvi...

  • Page 27: General Information

    5045-001 1. General Information The Optra™ C is a 600 dpi Color Laser printer designed to attach to IBM-compatible PC’s and to most types of computer networks. The one model is available with standard PostScript Level 2 emulation and PCL 5 emulation: A4 Mono A4 Full Color A4 Full Color...

  • Page 28: Maintenance Approach

    5045-001 Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. This printer can be serviced without being connected to a host computer.

  • Page 29: Service Checkpoints

    5045-001 Service Checkpoints Fuser Unit Point Tool/Solvent Remarks Delivery Guide Clean lightly to remove toner. Separation Claw Clean carefully, the tip Unit breaks easily. Entrance Guide Clean Cassette Pickup Unit Point Tool/Solvent Remarks Feed Roller Damp towel or Clean Separation alcohol Roller Transfer Drum Holder Unit...
  • Page 30 5045-001 Drum Cartridge Point Tool/Solvent Remarks Photoconductor Toner Clean, do not use water or solvents and do not contaminate with solvents or oil. When removing the drum store it in the drum cover. Manual Feeding Tray Pickup Unit Point Tool/Solvent Remarks Separation Pad Dry towel...

  • Page 31: Tools

    5045-001 Tools The removal and adjustment procedures described in this manual require the following tools and equipment: • Magnetic tip Phillips screwdrivers large and small • Flat-blade screwdriver • Fuse puller • Analog or digital volt ohmmeter • Oil syringe and bottle •...

  • Page 32: Abbreviations

    5045-001 Abbreviations ASIC Application-Specific Integrated Circuit Customer Setup DRAM Dynamic Random Access Memory EPROM Erasable Programmable Read Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit HVPS High Voltage Power Supply Local Area Network LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode...

  • Page 33: Diagnostic Information

    5045-001 2. Diagnostic Information Diagnostic/Maintenance Approach This printer can be serviced without being connected to a host computer. This printer will display both operator correctable errors and service errors on the front (operator) panel. In addition, there are tests available from the density adjustment panel on the back of the machine that bypass the video controller board.
  • Page 34 5045-001 DC Controller Board Information The DC controller board (DCCB) controls the printer. When the PRINT signal is received from the video controller board, the DCCB sends the print sequence command to the mechanical controller board (MCB) which starts controlling the various loads. The DC controller board retains important information in EEPROM concerning drum life, oil out warnings, registration adjustments, and so on.
  • Page 35 5045-001 Mechanical Controller Board Information The mechanical controller board (MCB) controls the various loads in response to signals received from the DC controller board (DCCB). The MCB then returns the status signals to the DCCB. The MCB controls the pick-up PCB, the high voltage power supply PCB, and the paper feeder driver PCB by way of the serial communication.

  • Page 36: Start

    5045-001 Start Use the error message table, symptom table, service checks, in this chapter and the diagnostic aids in Chapter 3 to determine the corrective action to repair a printer. If the operator panel is blank, black or appears unusual, unplug the video controller board and run the engine print tests using the Density Adjustment Panel.

  • Page 37: Operator Codes

    5045-001 Operator Codes The following code numbers are operator instructions and messages. In some cases, no action is required; others are operator-correctable; and others may require service. An error code may require up to one minute to appear. Some symptoms may not generate an error code.
  • Page 38 5045-001 Code Symptom Waste Bottle Full Check for: • Full bottle • Improper installation • Missing bottle • Broken interlock • Toner on window of bottle (Use a clean, dry rag to clean the window. Do not use finger.) Oil Bottle Empty/Missing Check to ensure the bottle is not empty.
  • Page 39 5045-001 Code Symptom Toner Cartridge Not Correctly Installed If there is a problem with one or more toner cartridges, check the following: 1. The latch at the rear that keeps the cartridge cover locked. 2. The hook at the rear that locks the cartridge into the rotary assembly.

  • Page 40: Power-On Self Test (Post)

    5045-001 Power-On Self Test (POST) When you turn the printer on, it performs a Power-On Self Test (POST). Check for correct POST functioning by observing the following: 1. All Operator Panel segments turn on from the top row down then clear. 2.
  • Page 41 5045-001 13. After the patches are read by the Density Sensor, the Cleaning Brush mechanism is pressed against the drum and the Cleaning Brush Motor is energized. 14. The calibration process is repeated this time starting at MINIMUM density and going to MAXIMUM density. At the end of this cycle the Cleaning Brush Mechanism is pressed and the Cleaning Brush Motor is energized.

  • Page 42: Error Message Table

    5045-001 Error Message Table Error Message Action Toner cartridge not “Error (46) Toner Cartridge Not correctly installed Installed Correctly” on page 2-14. Fuser, warm-up See “Error (111/112) Fuser, Warm- Temperature low Up/Temperature Low” on page 2-15. Fuser, warm-up See “Error (111/112) Fuser, Warm- Temperature low Up/Temperature Low”...
  • Page 43 5045-001 Error Message Action Main motor start-up or See “Error (132/133) Main Motor rotation (M2) Start-Up or Rotation” on page 2-23. Main motor start-up or See “Error (132/133) Main Motor rotation (M2) Start-Up or Rotation” on page 2-23. Controller fan motor See “Error (134) Controller Fan failure Motor Failure”...

  • Page 44: Symptom Table

    5045-001 Symptom Table Symptom Action Background Go to “Background” on page 2-54 Black Go to “Black Service Check” on page 2-61 Blank Page Go to “Blank Page Service Check” on page 2-62 Blank Spots Go to “Blank Spots Service Check” on page 2-63 Color Aberration Go to...
  • Page 45 5045-001 Symptom Action No Manual Feed Go to “No Pickup (Manual Feed)” on page 2-31 No Optional Feeder Paper Pickup Go to “No Pickup (Manual Feed)” on page 2-31 Paper Feed Problems In Pickup Go to “Paper Feed Area Troubleshooting” on page 2-38 Paper Feed Problems In Drum Go to “Transfer Drum Unit”...

  • Page 46: Service Checks

    5045-001 Service Checks Error (46) Toner Cartridge Not Installed Correctly Action Cartridge(s) Check for broken locating pins. If the cartridge appears OK, try a different one or set. Carousel brake Check the brake clutch (Asm 16, Ref 9) for continuity. Check the wiring to the mechanical controller board.

  • Page 47: Error (111/112) Fuser, Warm-Up/Temperature Low

    5045-001 Error (111/112) Fuser, Warm-Up/Temperature Low Action Check the connections of DC controller PCB Poor connection connector J112 and mechanical controller PCB connector J2007. Reconnect them. Thermistor/ Turn the power switch OFF, remove the fuser unit, wiring and measure the resistance between fuser unit connectors J21-5 and J21-6, see “Fuser Connector (J21)”...

  • Page 48: Error (113) Fuser Temperature High

    5045-001 Error (113) Fuser Temperature High Action Thermistor Turn the power switch OFF, and remove the fuser short unit. Measure the resistance between fuser unit connectors J21-5 and J21-6, see “Fuser Connector (J21)” on page 5-37. Is it 1 Ohm or less? Check the wiring between DC controller PCB connector J112 and the thermistor, and if it is normal, replace the thermistor.

  • Page 49: Error (115) Fuser Heater Off

    5045-001 Error (115) Fuser Heater Off Action Fuser upper Turn the power switch OFF, and remove the fuser heater / unit. Is there continuity between fuser unit Thermoswitch connectors J21-1 and J21-2? See “Fuser Connector (J21)” on page 5-37. Check the continuity of both the fuser upper heater and the thermoswitch, and replace defective parts.

  • Page 50: Error (117) Fuser Pump Failure

    Use of a spray contact cleaner in most instances will allow normal functioning of the fuser sensors, which have been contaminated with silicone oil. The only cleaner currently approved by Lexmark is CRC brand industrial contact cleaner # 03130. 2-18...
  • Page 51 5045-001 In addition to the cautions on the Material Safety Data Sheet (MSDS) label attached to the can, observe the following guidelines: • When spraying either fuser sensor (PS9 or PS10), place a piece of absorbent material below the sensor to catch the excess spray.

  • Page 52: Error (121/125) Laser Board Failure

    5045-001 Error (121/125) Laser Board Failure Note: A 125 error may occur due to temperature extremes and may be of a temporary nature. Check the error log. • If it is a one time occurrence, POR the printer to see if it resets. •...

  • Page 53: Error (123/124) Mirror Motor Start-Up Or Rotation

    5045-001 Error (123/124) Mirror Motor Start-up or Rotation Action Poor connection Check the connection on the DC controller PCB connector J102. Reconnect it. Power supply Are there approximately 24 V dc between DC unit (low controller PCB connectors J102-10 (24 V) and voltage) J102-5 (GND)? Check whether +24 V dc is being supplied between DC controller PCB connectors...

  • Page 54: Error (126/131) Transfer Drum Motor Failure

    5045-001 Error (126/131) Transfer Drum Motor Failure Action Poor connection Check the connection on the mechanical controller PCB connector J2015. Reconnect it. Door switch Turn the machine off and unplug the power cord. Disconnect connector J7 from the power supply unit. When you turn the door switch (SW2) ON, is there continuity between connectors J7-1 (+24VB) and J7-2 (+24VA)? Replace the door switch.

  • Page 55: Error (132/133) Main Motor (M2) Start-Up Or Rotation

    5045-001 Error (132/133) Main Motor (M2) Start-Up or Rotation Action Poor connection Check the connection on the mechanical controller PCB connector J2013. Reconnect it. Door switch Turn the machine off and disconnect the power cord. Disconnect connector J7 from the power supply unit. When you turn the door switch (SW2) ON, is there continuity between connectors J7-1 (+24VB) and J7-2 (+24VA)? Replace the door switch.

  • Page 56: Error (135) Fuser Unit Fan Motor Failure

    5045-001 Error (135) Fuser Unit Fan Motor Failure Action Poor connection Check the connection of mechanical controller PCB connector J2012. Reconnect it. Fuser unit fan Turn the machine off. Disconnect mechanical controller PCB connector J2012. Immediately after Mechanical turning the power switch ON, does the voltage controller PCB between mechanical controller PCB connectors J2012-3 and J2012-1 (GND) change from OV to...

  • Page 57: Error (141) Power Supply Failure (Lvps 110V Or 220V)

    5045-001 Error (141) Power Supply Failure (LVPS 110V or 220V) Action Wrong fuser Turn the power switch OFF, and remove the fuser unit unit. Do the power supply rated voltage and fuser (New fuser or unit rated voltage correspond? Replace the fuser machine) unit so that it corresponds to the power supply rated voltage.

  • Page 58: Error (143) 5 V / 24 V Supply Failure

    5045-001 Error (143) 5 V / 24 V Supply Failure Action Power supply Check the connections on the DC controller PCB unit (low connector J101 and power supply unit connector J4. voltage) Replace and check as follows: DC controller 1. Power supply unit. 2.

  • Page 59: Error (146) Printer Communication Failure

    5045-001 Error (146) Printer Communication Failure Action Paper feeder Check to ensure the paper feeder is latched in place, (printer) and the self docking connector is not damaged. Mechanical Check the connections on the DC controller PCB controller connector J112 and mechanical controller PCB connector J2007.

  • Page 60: Error (148) Developer Unit Rotation Failure

    5045-001 Error (148) Developer Unit Rotation Failure Action Poor connection Check the connection on the mechanical controller PCB connector J2016. Reconnect it. Door switch Turn the machine off and disconnect the power cord. Disconnect connector J7 from the power supply unit. When you turn the door switch (SW2) ON, is there continuity between connectors J7-1 (+24VB) and J7- 2 (+24VA)? Replace the door switch.

  • Page 61: Error (149) Developer Unit Pressure Failure

    5045-001 Error (149) Developer Unit Pressure Failure Action Poor connection Check the connection on the mechanical controller PCB connector J2016. Door switch Turn the machine off and disconnect the power cord. Disconnect connector J7 from the power supply unit. When you turn the door switch (SW2) ON, is there continuity between connectors J7-1 (+24VB) and J7- 2 (+24VA)? Replace the door switch.

  • Page 62: No Ac Power/Dead Machine

    5045-001 No AC Power/Dead Machine Action On/Off switch Be sure connector J6, see “Connector Locations” on connector page 5-14, is connected into the LVPS. This connector will sometimes fall off the LVPS when working in this area. Power supply Check voltage at the outlet. Inform the user that rated voltage is not supplied at the outlet.

  • Page 63: No Dc Power

    5045-001 No DC Power Action AC power Unplug the power cable. Is AC power being supplied supply to this cable? Check AC power. Wiring Turn the power switch OFF, and disconnect connectors J3, J4, and J5. Plug in the power cable, DC load and turn the power switch ON.

  • Page 64: No Pickup (Cassette Feed)

    5045-001 No Pickup (Cassette Feed) Action Gear Is the pickup motor drive properly transmitted by the gears? Check the gears, and replace any damaged ones. Pickup motor Does the pickup motor rotate? Pickup PCB 1. Check the connection of pickup PCB connector J304, and if it is normal replace the pickup motor.

  • Page 65: Registration Roller Does Not Rotate

    5045-001 Registration Roller Does Not Rotate Action Gear train Is the pickup motor drive properly transmitted by the gears? Check the gears, and replace any damaged ones. Pickup PCB Turn the power switch OFF, remove the pickup unit, and disconnect the connector J34. Measure the Registration resistance between cable connectors J34-1 and roller clutch...

  • Page 66: Pickup / Feed System Theory

    5045-001 Pickup / Feed System Theory When the /PRNT signal is sent to the DC controller by the video controller and the scanner motor is put in the READY state, the DC controller issues the print sequence command to the mechanical controller, which then starts printing.
  • Page 67 5045-001 The paper feed route can be divided into 3 sections: 1. Pickup unit, 2. Transfer drum unit, 3. Fusing/delivery unit. Diagnostic Information 2-35...
  • Page 68 5045-001 OHP Sheet Detection (transparency) When an OHP sheet is used for this printer, the dedicated one must be used with a white band at its leading edge. The following determinations are made by measuring the time period that light emitted from the paper top sensor (PS303) is shielded by this band, and whether it is: •...
  • Page 69 5045-001 Diagnostic Information 2-37...

  • Page 70: Paper Feed Troubleshooting

    5045-001 Paper Feed Troubleshooting Pickup Unit (Codes 20 - 21, Paper Jam) Action Paper Is recommended paper being used? Advise the customer to use recommended paper. Paper Is the paper deformed with curls or waves? Replace the paper. Advise the user on the storage method.
  • Page 71 5045-001 Action Paper Is the paper folded? Replace the paper. Excessive Is more print paper in the cassette than paper in suggested? Advise the user not to put more cassette than the suggested amount of paper in the cassette. Cassette Is the cassette pickup roller, the separation pickup roller, roller, or the feed roller worn or deformed? If...

  • Page 72: Transfer Drum Unit

    5045-001 Transfer Drum Unit (Codes 22 - 23, Paper Jam) Action Gripper Is the gripper damaged? Replace the gripper. Gripper Does the gripper properly open and hold the paper? Check whether: • The gripper hold-down spring is deformed or disconnected. •...

  • Page 73: Fuser/Delivery Unit

    Use of a spray contact cleaner in most instances will allow normal functioning of the fuser sensors, which have been contaminated with silicone oil. The only cleaner currently approved by Lexmark is CRC brand industrial contact cleaner # 03130. In addition to the cautions...

  • Page 74: Fuser

    5045-001 Fuser Action Fuser roller Do the fuser rollers rotate smoothly? Check Drive unit the fuser roller drive unit. Fuser rollers Is the fuser upper roller or the fuser lower roller deformed or flawed? If yes, replace them. Fuser entrance Is the entrance guide soiled? Is there a guide guide protrusion due to a flaw or toner adhesion?

  • Page 75: Multi-Feed

    5045-001 Multi-Feed Action Paper Is recommended paper being used? Advise the user to use recommended paper. Location Does it occur in the manual feeding tray? Check step 5. (Cassette, check step 4). Cassette Is the print paper placed properly against the cassette claw? Place the paper correctly.

  • Page 76: Wrinkles

    5045-001 Wrinkles Action Paper Is recommended paper being used? Advise the user to use recommended paper. Paper Do the wrinkles disappear when you use new paper? As the paper probably was moist, advise the user on the correct storage method. Pickup unit Open the front cover while the paper is between the pickup and fuser units.

  • Page 77: Skewing

    5045-001 Skewing Action Paper Is recommended paper being used? Advise the user to use recommended paper. Cassette Is the cassette set properly? Set it correctly. Excessive Is more paper place at the pickup slot than paper suggested? Advise the user not to set more than the (manual) suggested amount of paper.

  • Page 78: Error Codes - 9Xx

    5045-001 Error Codes - 9XX Error (900) Software Error Description Action This can occur when: Feed the correct size paper. • The paper being fed is a After turning the machine off, wait different size than selected at least 10 seconds before turning by the Setup Menu.

  • Page 79: Error (946) Service Rip Board

    5045-001 Error (946) Service RIP Board Description Action ASIC 2 failure Replace the Video Controller Board. Error (947) Service RIP Board Description Action ASIC 3 failure Replace the Video Controller Board. Error (948) Service RIP Board Description Action Compress/ Replace the Video Controller Board. Decompress failure Error (949) Service RIP Board...

  • Page 80: Error (950) Service Rip Board

    5045-001 Error (950) Service RIP Board Description Action SRAM failure Replace the Video Controller Board. Error (953) Service RIP Board Description Action NVRAM failure Replace the Video Controller Board. Error (955) Service Video RAM Error Description Action Video RAM Replace the Video Controller Board. failure Error (956) Service L2 Cache Error Description...

  • Page 81: Error (961) Bad / Missing Dram

    5045-001 Error (961) Bad / Missing DRAM Description Action Bad or missing Replace the optional DRAM. DRAM in the optional DRAM slot Error (970/979) INI Failure Description Action INA failure Replace INA. Error (977) Service Network Board Description Action Bad network This error message indicates a bad Network board board is installed in the Network board slot.

  • Page 82: Print Quality

    5045-001 Print Quality Before you perform the following service checks, do the following: • Be sure the paper or transparencies are the recommended finish and weight. If the paper weight is incorrect (too stiff), it may not provide 100% adhesion to the transfer drum. The trailing edge will not be attracted to the drum and will “flap”...

  • Page 83: Gradation Test

    5045-001 Gradation Test This test shows the presence of horizontal voids. Do not confuse a void (which is a missing laser scan line) with small horizontal variations in density called “jitter”, (see example on following page). • If voids are present, go to “Horizontal Voids Service Check”...

  • Page 84: Horizontal Variation ("Jitter") Example

    5045-001 Horizontal Variation (“Jitter”) Example (Color may vary depending upon your monitor or system.) 2-52...

  • Page 85: Solid Color Test

    5045-001 Solid Color Test This test indicates which cartridge(s) is/are contributing to background problems. It also shows which of the four cartridges has reached end-of-life. The test produces a solid band of each color, approximately 2 1/4 inches (60 mm) long. Each color should be a uniform color with no vertical streaks.

  • Page 86: Print Quality Troubleshooting

    5045-001 Print Quality Troubleshooting Background Symptom: A slight tint to the entire page starting approximately 8 mm from the top edge of the page. It may appear to be gray, but could be any combination of primary colors. Cause: Cool, dry environments or used cartridges nearing end of life. Resolution: Increase environmental temperature and humidity.

  • Page 87: Black Vertical Lines

    5045-001 Black Vertical Lines Symptom: Thin vertical black lines of any length, anywhere on the page. Cause: Worn out or damaged photoconductor. This may be caused by the photoconductor reaching end-of-life or damage resulting from a severe paper jam. Resolution: Replace the photoconductor.

  • Page 88: Laser Failures

    5045-001 Laser Failures Symptom: Jagged test and edges or very fine horizontal lines the entire width of the page. These may occur as blank lines (voids) or as any color. Vertical print may be wavy (see following example). Cause: Contaminated (toner) beam detect mirror, or beam detect lens in the printhead, causes the laser to loose sync or power aberration.

  • Page 89: Oil Soaking

    5045-001 Oil Soaking Symptom: Certain printers may demonstrate a condition that makes the top (leading) edge of the first page appear to have been dipped in oil. This oil stain is not to be confused with random oil spots. The soaking may be so small as to be unnoticeable, except in certain areas across the leading edge of the page.

  • Page 90: Random Oil Spots On Page

    5045-001 Random Oil Spots on Page This condition usually occurs following a long idle period or power saver mode. Symptom: Random oil spots on paper may cause customer complaints. Cause: • Failure of machine to evenly distribute silicon oil over both fuser rollers.

  • Page 91: Vertical Streaks

    5045-001 Vertical Streaks Note: Run the “Gradation Test” from the density adjustment panel. Symptom: Severe vertical voids in the text, or graphics, (see example on following page). This may occur on a single color, every color, or any combination. Cause: Cartridge(s) nearing end-of-life.
  • Page 92 5045-001 Vertical Streaks Example (Color may vary depending upon your monitor or system.) 2-60...

  • Page 93: Print Quality Service Checks

    5045-001 Print Quality Service Checks Black Service Check Action Photoconductor Replace the photoconductor. If problem remains, check the primary charging contact spring, the photoconductor contact, the primary charging contact plate and spring. High-voltage Check the continuity between the photoconductor cable / resistor drum contact and the high-voltage PCB J1004-3.

  • Page 94: Blank Page Service Check

    5045-001 Blank Page Service Check Action Front cover Check the shutter open-close boss for damage, back panel replace the front cover back panel if necessary. Laser beam Check the shutter and the shutter arm for proper shutter, shutter operation, replace if necessary. High-voltage Check the continuity between the developing bias cable / resistor...

  • Page 95: Blank Spots Service Check

    5045-001 Blank Spots Service Check Action Paper Is recommended paper being used? Print with recommended paper. If the outcome is good, ask the user to use recommended paper. Paper Is the paper damp? Replace the paper. Toner cartridge Does it appear for a specific color only? Replace the toner cartridge of the color for which it appears.

  • Page 96: Dark Image Service Check

    5045-001 Dark Image Service Check Action Density sensor Operate the density adjustment panel to adjust the unit density. Clean the density sensor lens. If the problem remains, replace the density sensor unit. High-voltage Clean the transfer drum ground contact and the power supply photoconductor contact.

  • Page 97: Dirt On Back Of Paper Service Check

    5045-001 Dirt On Back Of Paper Service Check Action Paper Paper must be the correct weight, see “Print Quality” on page 2-50. Lower fuser “Spacing Table Service Check” on page 2-69 roller aid in diagnosing the dirty or failing FRU. Attraction roll Check the cleaning brush is not damaged and there is no paper in the cleaning assembly.

  • Page 98: Dirty Print Service Check

    5045-001 Dirty Print Service Check Action Fuser cleaning Check the cleaning belt for proper operation and belt condition. Replace if necessary. Fuser upper “Spacing Table Service Check” on page 2-69 roller aid in diagnosing the dirty or failing FRU. Photoconductor Toner cartridge Attraction roller Poor attraction/...

  • Page 99: Distortion Service Check

    5045-001 Distortion Service Check Action Poor connection Is the connection good between DC controller PCB connector J208 and connectors J102, J110 and J111? Laser/scanner Is the connection good between laser/scanner unit unit and DC controller connectors J401, J402, J451 and J701? Replace and check in the following order: DC controller 1 Laser/scanner unit...

  • Page 100: Light Image Service Check

    5045-001 Light Image Service Check Be sure the printer is not installed in an unusually hot or cold environment, see the User’s Reference . If the problem is with one color, try a new toner cartridge of that color. Action Density sensor Operate the density adjustment panel to adjust the unit...

  • Page 101: Poor Fusing Service Check

    5045-001 Poor Fusing Service Check Action Fuser upper Does the defect appear vertical and in a line? Check roller for flaws on the upper and lower rollers. Fuser lower Is the fuser lower roller soiled? Clean the roller. roller Replace it if you cannot clean it. Oil applying unit Is oil uniformly applied to the fuser upper roller? Check the operation of the oil applying unit.

  • Page 102: Streaking Service Check

    5045-001 Streaking Service Check Streaking is described as small particles or streaks pointing downward from multicolored, horizontal lines. It appears as if the lines were “squashed” together. This should not be confused with cartridge streaking. Action Paper Replace the paper. Is the paper damp? Separation...

  • Page 103: Toner Scattered Service Check

    5045-001 Toner Scattered Service Check Note: This condition is also known as “spew”. It appears as a halo around dense characters. This condition is worsened by cool, dry conditions. Action Paper Is recommended paper being used? Print with recommended paper. If the outcome is good, ask the user to use recommended paper.

  • Page 104: Vertical Lines Service Check

    5045-001 Vertical Lines Service Check Note: Also see “Vertical Streaks” on page 2-59. Action Toner cartridge In which colors do the vertical lines appear? Replace the cartridges of the colors affected. Note: This can occur when cartridges are used at very low color coverage percentages, for extended (greater than 4K page) intervals.

  • Page 105: Vertical Voids Service Check

    5045-001 Vertical Voids Service Check Action Toner cartridge Does a white vertical line appear for all colors? Remove the cartridge of the color for which it appears from the printer. Shake the cartridge and put it back in the printer. Replace the cartridge if the line reappears.

  • Page 106: Diagnostic Aids

    5045-001 3. Diagnostic Aids This printer has three different methods of running diagnostics. The printer can run internal diagnostics tests. These tests are in the same format as the other Optra models and are described in this chapter. These tests work in conjunction with the “Power-On Self Test (POST)”...

  • Page 107: Diagnostics Mode

    5045-001 Diagnostics Mode To run the printer diagnostic tests, you must put the printer in Diagnostics mode. The Video Controller board must be plugged into the connector board (normal state). Note: Entering the Diagnostic mode clears NVRAM. To enter Diagnostics mode: 1.

  • Page 108: Diagnostics Mode Menu Structure

    5045-001 Diagnostics Mode Menu Structure The following is the Diagnostics mode menu structure, The indented items are submenus available under the main menu items, which are in capital letters on the operator panel. Menu items referring to options will only be present if those options are installed. Menus with more than four items will use [MORE] on the fourth operator panel button to access the next screen of selections.

  • Page 109: Diagnostics Mode Tests

    5045-001 Diagnostics Mode Tests Button Test To test the operator panel buttons: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [Button Test]. 4. Press each button. [Closed] is displayed until the button is released. Then [Open] is displayed. 5.

  • Page 110: Defaults

    5045-001 Defaults Allows setting the following defaults to U.S. or Non-U.S. values. U.S. NON U.S. Letter size paper A4 paper Symbol Set Roman-8 Symbol Set PC-850 To set the defaults: 1. Enter Diagnostics mode. 2. Select [PRINTER SETUP]. 3. Select [Defaults]. 4.

  • Page 111: Error Log

    5045-001 Error Log The list of the six most recent errors is displayed. The newest error is displayed in position one. In a full log, position six is the oldest error. If more than six errors are received, the oldest error is discarded. If a position is all zeros, not enough errors have occurred to fill up the log to that position.

  • Page 112: Lcd Test

    5045-001 LCD Test To test the operator panel display: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [LCD Test]. 4. Select [Single] or [Continuous]. 5. The display goes through a continuous sequence of turning pels on and off. 6.

  • Page 113: Permanent Page Count

    5045-001 Permanent Page Count The permanent page count can be only displayed. It cannot be modified or reset by the customer or servicer. To view or set the page count: 1. Enter Diagnostics mode. 2. Select [PAGE COUNTS]. 3. Select [Permanent Page Count]. 4.

  • Page 114: Print Test 2

    5045-001 Print Test 2 Print Test 2 generates ten printouts: Four pages of each color at high density, four pages of each color at medium density and two pages of multi color that fade away. All of these can be used to evaluate banding or other print quality problems.

  • Page 115: Quick Disk Test

    5045-001 Quick Disk Test This test performs a non-destructive write/read on one block per track on the disk. The test will read one block on each track, save the data, and proceed to write and read four test patterns to the bytes in the block.

  • Page 116: Wrap Tests

    5045-001 Wrap Tests The Wrap Tests check the circuits used to communicate with the host computer. To run the Wrap Test: 1. Turn the printer off. 2. Disconnect the interface cable. 3. Install the wrap plug in one of the interface cable connectors. •...

  • Page 117: Other Tests

    5045-001 Other Tests Density Adjustment Panel On the rear of the printer, the density adjustment panel is used for density adjustment, test pattern selection, and service technician printer adjustment. Diagnostic Aids 3-12...
  • Page 118 5045-001 1. TEST PRINT key. Press the key to print a test pattern. 2. ENTER key. Press the key to input the currently selected value. 3. +/- key. Use when changing the density or selecting a print test pattern. 4. COLOR SELECT key. Press the key to the desired color to change the density.
  • Page 119 5045-001 Density Adjustment 1. Press the COLOR SELECT key and select the color of your choice. The LEDs light indicating the selected color and that density. 2. Select the density by the + key or - key. When the selected density differs from that currently set in the printer, the Density gauge LED flashes.
  • Page 120 5045-001 When the printer is turned ON, or the density adjustment panel is not operated for at least 30 seconds, it enters the OFF state. When OFF, the COLOR SELECT LEDs go OFF and only the Density gauge DEFAULT LED (middle) lights if all the colors are set at the factory-shipping value, or otherwise all LEDs will go OFF.
  • Page 121 5045-001 2. Decide on a test print pattern by using the + key or - key. When the test print pattern differs from that currently selected in the printer, the Density gauge LED will flash. The correspondence between the Density gauge LEDs and each test print pattern is as follows.
  • Page 122 5045-001 Separation Voltage Control Designation 1. While holding down the COLOR SELECT key, press the ENTER key 3 times. The "Y" and "Bk" COLOR SELECT LEDs flash to indicate that the Separation voltage control designation mode has been entered. 2. Select the separation voltage control method by the + key or - key.
  • Page 123 5045-001 3. Determine the separation voltage control method by the ENTER key. The Density gauge LED lights and the printer changes the separation voltage control method. Diagnostic Aids 3-18...
  • Page 124 5045-001 Service Technician Adjustment Initialize as the service technician adjustment mode, and that function operates instead of the density adjustment function. At this time, the "Bk" indicator flashes to indicate the service technician adjustment function if the panel is not OFF. 1.
  • Page 125 5045-001 3. Decide on an adjustment value by using + key or - key. When the adjustment value differs from that currently set in the printer, the Density gauge LED flashes. The relationship between each adjustment item and value is as follows. a.

  • Page 126: Lan Information

    5045-001 LAN Information The printer may be connected to one of the following LAN types: Token-Ring Ethernet 10BASE-T Ethernet 10BASE2 LocalTalk The Network external connectors are shown below. The printer test page also indicates to which type of LAN the printer is connected. 3-21...

  • Page 127: Repair Information

    5045-001 4. Repair Information This chapter contains adjustments and removal procedures. Whenever parts are replaced, make sure that all adjustments are correct by running diagnostics procedures and checking adjustments as needed. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).

  • Page 128: Adjustments

    5045-001 Adjustments Density Adjustment Panel “Density Adjustment Panel” on page 3-12. There are no mechanical adjustments. Service Information Releasing Plastic Latches Many of the parts are held in place with plastic latches. To remove such parts, press the hook end of the latch away from the part to which it is latched.

  • Page 129: Removal Procedures

    5045-001 Removal Procedures The removals in this section are arranged in alphabetical order. To install parts, reverse the removal procedure, giving attention to any special conditions listed. When reinstalling the drive gear solenoid assembly removed in step 9, rotate the main drive motor (M2) counterclockwise after installing the 4 screws.

  • Page 130: Cassette Paper Pickup Drive Motor

    5045-001 Cassette Paper Pickup Drive Motor See Assembly 24-9. 1. Open the multipurpose paper pickup door. 2. Release the two green cassette latches. 3. Slide the cassette out enough to remove the two retaining brackets and remove the cassette assembly. 4.

  • Page 131: Cassette Paper Pickup Pcb

    5045-001 Cassette Paper Pickup PCB See Assembly 24-13. 1. Open the multipurpose paper pickup door. 2. Release the two green cassette latches. 3. Slide the cassette out enough to remove the two retaining brackets and remove the cassette assembly. 4. Tip the cassette back and remove the three bottom cover screws and the cover.

  • Page 132: Cassette Paper Pickup D-Rollers

    5045-001 Cassette Paper Pickup D-rollers See Assembly 24-2. 1. Open the multipurpose paper pickup door. 2. Release the two green cassette latches. 3. Slide the cassette out enough to remove the two retaining brackets and remove the cassette assembly. 4. Tip the cassette back and remove the three bottom cover screws and the cover.

  • Page 133: Cassette Paper Pickup Solenoid

    5045-001 Cassette Paper Pickup Solenoid See Assembly 24-10. 1. Open the multipurpose paper pickup door. 2. Release the two green cassette latches. 3. Slide the cassette out enough to remove the two retaining brackets and remove the cassette assembly. 4. Remove the two screws and the motor drive cover. 5.

  • Page 134: Cover Removals

    5045-001 Cover Removals Remove the power cord before continuing. 1. Open the fuser door and remove the two screws [A] securing the top cover.
  • Page 135 5045-001 2. Open the front cover and lift the top access cover. Repair Information 4-9...
  • Page 136 5045-001 3. With the top access cover raised, unsnap the plastic link [A]. Remove the top cover trim [B]. Remove the top cover by lifting the right side slightly, while moving the top cover to the right. 4-10...
  • Page 137 5045-001 4. Remove the two screws [A] and remove the left cover. Repair Information 4-11...
  • Page 138 5045-001 5. Release the two latches [A] and remove the rear cover. 4-12...
  • Page 139 5045-001 6. Remove the nine screws [A] and remove the EMC shield. Repair Information 4-13...

  • Page 140: Dc Controller Pcb

    5045-001 DC Controller PCB Note: Do not replace this board unless directed to do so by an error code 147 Engine Board IC Failure. Other errors may call for the DC controller to be replaced as part of the ordered FRU replacement. 1.
  • Page 141 5045-001 3. Remove the nine screws [A] from the connector board cover (Asm 5-2) and remove the cover. Repair Information 4-15...
  • Page 142 5045-001 4. Disconnect the three cables [A] from the connector board. 4-16...
  • Page 143 5045-001 5. Remove the seven screws [A] securing the controller housing to the machine and remove the housing. During reassembly, be sure to thread the flat cable through the toroid before mounting the housing. Repair Information 4-17...
  • Page 144 5045-001 6. Release the ZIF connector [A] (J2007) on the mechanical controller PCB and remove the cable. 4-18...
  • Page 145 5045-001 7. Release the ZIF connectors (J103, J110 and J111) on the DC controller PCB and remove the cables. Do not remove J112. Repair Information 4-19...
  • Page 146 5045-001 8. Disconnect the remaining cables going to the board. Do not disconnect J108 or J112 unless you are replacing the PCB. These are not ZIF connectors. 4-20...
  • Page 147 5045-001 9. Remove the two screws [A] securing the cable guard and slide the guard slightly toward the center of the machine and remove Repair Information 4-21...
  • Page 148 5045-001 10. Remove the four board mounting screws [A] and the board. 4-22...

  • Page 149: Density Adjustment Panel

    5045-001 Density Adjustment Panel See Assembly 8-27. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Disconnect the wire cable from the density adjustment panel. 4.

  • Page 150: Developing Rotary Assembly

    5045-001 Developing Rotary Assembly See Assembly 27-1. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Open the front door and remove the two screws from the operator panel.

  • Page 151: Discharge Roller Drive Assembly

    5045-001 Reassembling Tips: 1. Install the front bearing first. Locate the bearing in position. While applying slight inward pressure to the bearing, rotate the center shaft until the pin in the bearing lines up with the slot in the center shaft. 2.

  • Page 152: Drive Gear Solenoid Assembly

    5045-001 Drive Gear Solenoid Assembly See Assembly 13. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the rear EMC shield. 4. Open the multipurpose paper pickup door. 5.

  • Page 153: Drum Cleaner Assembly

    5045-001 Drum Cleaner Assembly See Assembly 31-1. 1. Open the multipurpose paper pickup door. 2. Release two green latches and slide the paper feeder out as far as possible. 3. Unsnap and remove the small, black plastic cover located at the right side of the cleaning assembly.

  • Page 154: Drum Lift Assembly

    5045-001 Drum Lift Assembly Note: This assembly lifts the transfer drum into the photoconductor. See Assembly 19-1. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the transfer drum assembly. 2. Remove the top cover. 3. Remove the left side cover and the rear cover. 4.

  • Page 155: Fuser Assembly

    5045-001 Fuser Assembly See Assembly 32-1. 1. Open the multipurpose paper pick up door. 2. Release two green paper pickup cassette latches and slide the assembly out. 3. Open the fuser access door. 4. Release the fuser access door strap (push down and pull out on the top of the latch and slide up).

  • Page 156: Fuser Oil Bottle Case Assembly

    5045-001 Fuser Oil Bottle Case Assembly See Assembly 32-7. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Use the hypodermic syringe tool (11A2440) to withdraw the oil from the bottle case.

  • Page 157: Fuser Hot Rollers

    5045-001 Fuser Hot Rollers See Assembly 32-12, 32-13. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Follow the steps in the Fuser Lamps Removal procedure and remove the lamps.

  • Page 158: Fuser Thermo Switch

    5045-001 Fuser Thermo Switch See Assembly 32-14. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Remove the two screws from the input guide located on the lower left side of the fuser.

  • Page 159: Fuser Cleaner Assembly

    5045-001 Fuser Cleaner Assembly See Assembly 32-8. Note: Replace this assembly only if it breaks or malfunctions. When the machine has printed 60,000 pages or less, depending upon the ratio of paper to transparence, the fuser and other items must be replaced in order to maintain maximum print quality.

  • Page 160: Fuser Oil Apply Assembly

    5045-001 Fuser Oil Apply Assembly See Assembly 32-5. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Remove the two extension springs from the fuser oil apply housing (one at the front and one at the rear).

  • Page 161: Fuser Thermistor

    5045-001 Fuser Thermistor See Assembly 32-15. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Remove the two screws from the protective cover and remove the cover.
  • Page 162 5045-001 Note: Steps 12 through 14 may be skipped if an offset screwdriver is used to remove the screws behind the oil bottle case. 12. Use the hypodermic syringe tool (11A2440) to withdraw the oil from the bottle case. Also remove the square cap from the oil tray and withdraw the oil from the oil tray.

  • Page 163: Fuser Lamps

    5045-001 Fuser Lamps See Assembly 32-2. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Remove the two screws from the protective cover and remove the cover.
  • Page 164 5045-001 Note: Steps 12 through 14 may be skipped if an off-set screwdriver is used to remove the screws behind the oil bottle case. 12. Use the hypodermic syringe tool (11A2440) to withdraw the oil from the bottle case. Also remove the square cap from the oil tray and withdraw the oil from the oil tray.

  • Page 165: Fuser Oil Applying Input Assembly

    5045-001 Fuser Oil Applying Input Assembly See Assembly 32-4. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Remove the spring from the oil applying input assembly. 4.

  • Page 166: High Voltage Power Supply

    5045-001 High Voltage Power Supply See Assembly 2-26. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield. 4. Open the multipurpose paper pickup door, release the two green latches and slide the tray out as far as possible.

  • Page 167: Low Voltage Power Supply

    5045-001 Low Voltage Power Supply See Assembly 7-4. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield from the rear of the machine. 4.

  • Page 168: Mechanical Controller Pcb

    5045-001 Mechanical Controller PCB See Assembly 7-32. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield from the rear of the machine. 4.

  • Page 169: Multipurpose Feeder U-Turn Roller Assembly

    5045-001 Multipurpose Feeder U-Turn Roller Assembly See Assembly 25-6. 1. Open the multipurpose paper pickup door. 2. Release the two green cassette latches. 3. Slide the tray out as far as possible. 4. Remove the screw and the gear train cover. 5.

  • Page 170: Paper Delivery Assembly

    5045-001 Paper Delivery Assembly See Assembly 26-1. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Open the fuser access door. 3. Remove the connector from the front of the paper delivery assembly. 4. Remove the screw from the paper drive assembly and remove the assembly.

  • Page 171: Printhead And Printhead Board

    5045-001 Printhead and Printhead Board See Assembly 6-2. For cover removals, see “Cover Removals” on page 4-8. Also see “DC Controller PCB” on page 4-14. 1. Remove the top cover. 2. Disconnect the fan connector (J2010) from the mechanical controller PCB. 3.
  • Page 172 5045-001 11. Remove the screws [A] from the two grounding straps. 4-46...
  • Page 173 5045-001 12. Remove the four printhead mounting screws [A] and lift the printhead out of the machine. Repair Information 4-47...

  • Page 174: Printer Drive Assembly

    5045-001 Printer Drive Assembly See Assembly 16-1. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield from the rear of the machine. 4.

  • Page 175: Rotary Manual Feed Assembly

    5045-001 Rotary Manual Feed Assembly See Assembly 15-1. For cover removals, see “Cover Removals” on page 4-8. 1. Open the top cover and the front cover. 2. Remove the left side cover and rear cover. 3. Remove the EMC shield from the rear of the machine. 4.

  • Page 176: Rear Cooling Duct

    5045-001 Rear Cooling Duct See Assembly 7-2 and 7-3. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield form the rear of the machine. 4.

  • Page 177: Transfer Drum And Holder Assembly

    5045-001 Transfer Drum and Holder Assembly See Assembly 29-1. Note: This procedure removes the transfer drum assembly from the transfer drum holder assembly. 1. Remove the transfer drum and holder assembly. 2. Remove the 4 screws from the two transfer drum holder covers and remove the covers.

  • Page 178: Transfer Drum Separation Claw

    5045-001 Transfer Drum Separation Claw See Assembly 29-6. 1. Remove the transfer drum and holder assembly. 2. Remove the spring from the separation claw. 3. Remove the three screws from the separation claw and remove the claw. Note: During reassembly, place the solenoid link in the claw before installing the claw on the drum.

  • Page 179: Transfer Drum Attraction Roller

    5045-001 Transfer Drum Attraction Roller See Assembly 28-9. 1. Remove the transfer drum and holder assembly. 2. Remove the spring at each end of the attraction roller holder. 3. Remove the screw from the attraction roller mounting pin located on the lower left corner of the transfer drum holder front plate and remove the pin.

  • Page 180: Transfer Drum Sheet

    5045-001 Transfer Drum Sheet See Assembly 28-8. 1. Remove the transfer drum and holder assembly. 2. Remove the two springs from the attraction roller holder. 3. Remove the two springs from the discharge roller holder. 4. Remove the two extension springs holding the one end of the transfer drum sheet to the transfer drum.

  • Page 181: Transfer Drum Front And Rear Slide Assemblies

    5045-001 Transfer Drum Front and Rear Slide Assemblies See Assembly 28-2, 28-4. 1. Remove the transfer drum assembly. 2. Remove the two screws from the front or rear slide assembly and remove the slide. Transfer Drum Discharge Roller See Assembly 29-12. 1.

  • Page 182: Transfer Drum Gripper Assembly

    5045-001 Transfer Drum Gripper Assembly See Assembly 29-2. Note: Also order a transfer sheet, since damage to the sheet may occur when removing it from the gripper assembly. 1. Remove the transfer drum and holder assembly. 2. Remove the two springs from the attraction roller holder. 3.

  • Page 183: Transfer Drum Solenoid

    5045-001 Transfer Drum Solenoid See Assembly 29-5. 1. Remove the transfer drum and holder assembly. 2. Remove the two springs from the attraction roller holder. 3. Remove the two springs from the discharge roller holder. 4. Remove the two extension springs holding the one end of the transfer drum sheet to the transfer drum.

  • Page 184: Transfer Drum Sensors

    5045-001 Transfer Drum Sensors See Assembly 29-3. Note: This sensor is used in two places on the transfer drum assembly. One of the sensors is on the inside of the drum and one on the outside of the drum. To remove the sensor on the inside of the drum, follow the removal procedure to remove the transfer drum solenoid (Asm 29-5) and remove the sensor.

  • Page 185: Transfer Drum Assembly

    5045-001 Transfer Drum Assembly See Assembly 29-1. 1. Open the front cover. 2. Remove the paper cassette. 3. Remove the waste toner bottle. 4. Remove the photoconductor unit. Note: Use the cover saved during installation to protect the photo- conductor from light. 5.
  • Page 186 5045-001 4-60...

  • Page 187: Transfer Drum Cleaning Drive Assembly

    5045-001 Transfer Drum Cleaning Drive Assembly See Assembly 17-1. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield from the rear of the machine. 4.

  • Page 188: Toner Cartridge Ejector

    5045-001 Toner Cartridge Ejector See Assembly 12-1. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the two screws from the operator panel and remove the operator panel. 2. Remove the front door. 3. Remove the top cover. 4.

  • Page 189: Upper Cooling Fan

    5045-001 Upper Cooling Fan See Assembly 7-7. For cover removals, see “Cover Removals” on page 4-8. 1. Remove the top cover. 2. Remove the screw that retains the fan grill operator panel bezel and remove the bezel. 3. Pry away the ESD shield from the fan housing. It is snapped on in 3 places.

  • Page 190: Optional Paper Feeder Removals

    5045-001 Optional Paper Feeder Removals The Optional Paper Feeder unit must be removed in order to perform the following removals. 1. Disconnect the power cord. 2. Remove the two lock pins. Note: Two persons should be used to lift the printer from the sheet feeder.

  • Page 191: External Covers

    5045-001 External Covers See Assembly 34. 1. Remove the cassette tray. 2. Open the Open/Close cover. 3. Remove the three screws and the front cover. 4. Remove the two screws and the rear cover. 5. Remove the two screws and the left cover. 6.
  • Page 192 5045-001 Paper Feeder Circuit Board See Assembly 36-6. 1. Remove the rear cover. 2. Remove the six screws and the gear cover. 3. Disconnect the three connectors under the gear cover. 4. Remove the three mounting screws and carefully slide the board and its mount out enough to disconnect the three connectors on the board.

  • Page 193: Paper Sensor Board

    5045-001 Paper Sensor Board See Assembly 35-17. 1. Remove the front pickup unit. 2. Disconnect the connector and disengage the claw holding the board. Pickup Roller(s) See Assembly 35-3. 1. Remove the front pickup unit. 2. Disengage the claw securing the pickup roller to the shaft and remove the roller.
  • Page 194 5045-001 Separation Roller Unit See Assembly 37-4. 1. Remove the cassette. 2. Open the Open/Close Door. 3. Remove the screw securing the separation roller unit and remove the separation unit. 4. Remove the E-clip and the bushing to remove the separation roller.

  • Page 195: Locations

    5045-001 5. Locations 1 Developing rotary unit 14 Fuser upper roller 2 Toner cartridge 15 Fuser lower roller 3 Laser / scanner unit 16 Fuser delivery roller 4 Photosensitive drum 17 Manual feed tray 5 Primary charging roller 18 Manual feed pickup roller 6 Drum cartridge 19 Separation pad 7 Cleaning unit...

  • Page 196: Switches

    5045-001 Switches...
  • Page 197 5045-001 Switches Name ASM - Index Function 3 - 9 Power switch 11 - 6 Door switch SW1601 3 - 8 * Ejection sensing switch SW2001 7 - 32 * Reset switch for mechanical controller PCB CSW1 3 - 8 * Cassette-size sensing switch 1 CSW2 3 - 8 *...

  • Page 198: Sensors

    5045-001 Sensors...
  • Page 199 5045-001 Sensors Name ASM - Index Function 25 - 9 Manual feeding paper sensor 25 - 9 Manual feeding paper size sensor 8 - 8 Toner cartridge position sensor 8 - 7 Developing rotary position sensor 26 - 3 Cleaning belt sensor 29 - 3 Attraction sensor, see “Transfer...
  • Page 200 5045-001 Name ASM - Index Function 32 - 14 Detects the fuser upper roller abnormal temperature 32 - 14 Detects the fuser lower roller abnormal temperature 2 - 22 Temperature / humidity sensor * Part of PCB...

  • Page 201: Clutches And Solenoids

    5045-001 Clutches and Solenoids Locations 5-7...
  • Page 202 5045-001 Clutches and Solenoids Name ASM - Index Function 16 - 9 Developing rotary brake clutch 16 - 8 Developing unit drive clutch 24 - 11 Registration roller clutch 16 - 5 Fuser unit drive clutch 24 - 10 Cassette feed solenoid 24 - 8 Manual feed solenoid 4 - 16...

  • Page 203: Motors And Fuser Heaters

    5045-001 Motors and Fuser Heaters Locations 5-9...
  • Page 204 5045-001 Motors and Fuser Heaters Name ASM - Index Function 24 - 9 Pickup motor 7 - 6 Main motor 16 - 7 Developing unit motor 16 - 6 Drum motor 31 - 2 Cleaning brush motor 35 - 19 Paper feeder motor 7 - 7 Fuser unit fan...

  • Page 205: Pcbs

    5045-001 PCBs Locations 5-11...
  • Page 206 5045-001 PCBs ASM - Name Function Index 1 DC Controller PCB 5 - 29 Controls printer functions (Laser/scanner control, Image stabilization control, fuser unit temperature control, video interface control, other various detection functions). 2 High-voltage power 2 - 26 Applies voltage in sequential supply PCB correspondence with primary charging, developing, transfer,...
  • Page 207 5045-001 ASM - Name Function Index 12 Ejection-sensing 3 - 8 Detects pulling of the ejection lever. 13 Video controller PCB 33 - 1 Processes input/output data between the printer and the external device. 14 Paper feeder driver 36 - 6 Drives the solenoids and the motors in the optional paper feed.

  • Page 208: Connector Locations

    5045-001 Connector Locations 5-14...
  • Page 209 5045-001 Connector Locations Locations 5-15...
  • Page 210 5045-001 Connector Locations 5-16...

  • Page 211: Dc Controller Board Connector Locations

    5045-001 DC Controller Board Connector Locations Name Function J 101 LVPS J 102 Laser Beam Detect / Motor J 103 Density Sensor J 104 Toner Low Detect (receive) J 105 Transfer Drum J 106 Cleaning Belt Sensor / Oil Sensor J 107 Waste Toner Sensing/ Cassette Size Sensing / Ejection Sensing...

  • Page 212: Dc Controller Board Connector Locations (Graphic)

    5045-001 DC Controller Board Connector Locations (Graphic) 5-18...
  • Page 213 5045-001 DC Controller Board Connectors (J101, J102, J103) J 101 J 102 J 103 LVPS Laser Beam Detect Density Sensor 1 GND 1 BDCHK 1 +5 V 2 +5 V 2 GND 2 DSNS 3 GND 3 /BD 3 /DENSEL 4 +24 VB 4 +5 V 4 GND...
  • Page 214 5045-001 DC Controller Board Connectors (J104, J105, J106) J 104 J 105 J 106 Toner Low Transfer Drum Cleaning Belt Detect Sensor (receive) Top Sensor 1 LEDDRV 1 TNSNS 13 +5 V 2 GND 2 GND 12 GND 3 WEBSNS 3 RET (+5 V) 11 /TOPREG Oil Sensor...
  • Page 215 5045-001 DC Connector Board Connectors (J107, J108, J109) J 107 J 108 J 109 Waste Tower Terminal Board Not Used Sensing 1 LEDON Video Interface 2 GND 1 through 37 3 HTSNS Cassette Size Sensing / Ejection Sensing 4 GND 5 /C SIZE 1 6 /C SIZE 2 7 /C SIZE 3...
  • Page 216 5045-001 DC Controller Board Connectors (J110, J111, J112) J 110 J 111 J 112 Laser Drive Board Laser Drive Board Mechanical Controller Board + 12 V 1 M6 1 Not Used + 12 V 2 GND 2 GND + 12 V 3 M5 3 GND 4 M4...
  • Page 217 5045-001 DC Controller Board Connectors (J113, J114) J 113 J 114 Not Used Density Adjustment Panel 1 /TST2 2 /LCK 3 /DSCK 4 /SDO 5 /SDI 6 GND 7 +5 V 8 /DSPEN Locations 5-23...

  • Page 218: Mechanical Controller Board Connector Locations

    5045-001 Mechanical Controller Board Connector Locations Name Function J2001 LVPS J2002 Paper Pickup Board J2003 Optional Sheet Feed J2004 HVPS J2005 Temperature / Humidity Sensor J2006 Rotary Position / Cartridge Position Sensor J2007 DC Controller Board J2008 LVPS J2009 Cleaning Belt Drive Solenoid and Fuser J2010 Controller Fan J2011...

  • Page 219: Mechanical Controller Board Connectors (Graphic)

    5045-001 Mechanical Controller Board Connectors (Graphic) Locations 5-25...
  • Page 220 5045-001 Mechanical Controller Board (J2001, J2002, J2003) J2001 J2002 J2003 Low Voltage Power Paper Pickup Optional Sheet Supply Board Feed 1 +24 VB 1 TXD 1 RES 2 GND 2 RXD 2 SEL 3 +5 V 3 CLK 3 Not Used 4 GND 4 GND 4 +5 V...
  • Page 221 5045-001 Mechanical Controller Bd (J2007, J2008, J2009) J2007 J2008 J2009 DC Controller Low Voltage Power Cleaning Belt Drive Board Supply Solenoid / Fuser 1 Not Used 1 FXSTS Fuser 2 PGND 2 SFSNS 1 THI 3 PGND 3 FXTYP 2 (THIRET) GND 4 +24 VA 4 THI 3 /FXSNS...
  • Page 222 5045-001 Mechanical Controller Bd (J2010, J2011, J2012) J2010 J2011 J2012 Controller Fan Fuser Drive Clutch Fuser Fan 1 GND 1 /FXON 1 GND 2 /FANLK3 2 +24 VA 2 FANLK1 3 FAND3 3 FAND1 Mechanical Controller Bd (J2013, J2014, J2015) J2013 J2014 J2015...
  • Page 223 5045-001 Mechanical Controller Bd (J2016, J2017, J2018) J2016 J2017 J2018 Developer Motor Toner Low Detect Not Used (beam) / Developing Rotary Brake Clutch / Developing Unit Drive Clutch 1 CA Brake Clutch 2 CB 1 /DEVBRK 3 AO 2 +24 VA 4 /AO 3 /DEVON 5 BO...

  • Page 224: Paper Pickup Board

    5045-001 Paper Pickup Board Name Function J301 Mechanical Controller Board J302 Manual Feed Size Sensor / Manual Feed Paper Sensor / Manual Feed Solenoid / Registration Roller Clutch J303 Cassette Feed Solenoid J304 Pickup Motor J305 Paper Top Sensor 5-30...
  • Page 225 5045-001 Paper Pickup Board Connectors (J301, J302, J303) J301 J302 J303 Mechanical Manual Feed Size Cassette Feed Sensor / Manual Controller Board Solenoid Feed Paper Sensor / Manual Feed Solenoid Sensor / Registration Roller Clutch 1 TXD Size Sensor 1 CPFED 2 RXD 1 LEDDRV2 2 +24 VC...

  • Page 226: Terminal Board

    5045-001 Terminal Board Name Function J801 Video Controller Board J802 DC Controller Board J803 Display Panel J804 Power Supply Terminal Board Connectors (J801, J802, J803) J801 J802 J803 Video Controller DC Controller Panel Display Board 1 through 96 1 through 37 A1 GRD Video Interface Video Interface...

  • Page 227: Optional Paper Feeder (Driver Board)

    5045-001 Optional Paper Feeder (Driver Board) Name Function J351 Option Connector J352 Paper Sensors J353 Feed Motor J354 Solenoid J355 Power Supply SW302 Right Door Switch SW301 Side Registration Adjusting Switch Optional Paper Feeder Driver Bd (J351, J352, J353) J351 J352 J353 Option Connector...

  • Page 228: Optional Paper Feeder (Miscellaneous)

    5045-001 Optional Paper Feeder (Miscellaneous) Name Function J312 Size Sensing PCB PS351 Cassette Paper Sensor J359 Paper Sensor Connector SL351 Cassette Feed Solenoid PS352 Pickup Sensor J358 Pickup Sensor Connector High Voltage Power Supply PCB 5-34...

  • Page 229: Separation Hvt Pcb

    5045-001 Separation HVT PCB Ejection Sensing PCB Cassette Size Sensing PCB Locations 5-35...

  • Page 230: Paper Feed Driver Pcb

    5045-001 Paper Feed Driver PCB 5-36...

  • Page 231: Fuser Connector (J21)

    5045-001 Fuser Connector (J21) Locations 5-37...

  • Page 232: Preventive Maintenance

    Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply • Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments...

  • Page 233: Lubrication Specifications

    Use of a spray contact cleaner in most instances will allow normal functioning of the fuser sensors which have been contaminated with silicone oil. The only cleaner currently approved by Lexmark is CRC brand industrial contact cleaner # 03130. In addition to the cautions...

  • Page 234: Maintenance, Customer Checks

    5045-001 Maintenance, Customer Checks Maintenance points that should be performed by the customer to maintain the printer at the optimum level are listed below. All other maintenance procedures are to be performed by a trained service technician. Item Action Toner Cartridge Shake or replace the cartridge.

  • Page 235: Parts Catalog

    7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are broken down 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 236: Covers

    Assembly 1: Covers...
  • Page 237 Asm- Part Index Number Units Description 11A2747 Cover, Pick Up, Lower 11A2140 Cover, Tray 11A2319 Cover, Bezel 11A2320 Cover, Rear 11A2321 Cover, LH Side 11A2322 Cover, Top 11A2323 Cover, Multipurpose Door 11A2324 Cover, Multipurpose Feeder Asm 11A2325 Multipurpose Feeder Asm 11A2327 Cover, Front 11A2328...

  • Page 238: Major Components

    Assembly 2: Major Components...
  • Page 239 Asm- Part Index Number Units Description Knob, Manual 11A2424 Bushing, PP 11A2379 Bushing, Front, PP 11A2379 Bushing, Rear, PP 11A2379 11A2425 Lever, Release Bushing, PP 11A2379 11A2717 Holder Spring, PP 11A2354 11A2741 Label, Caution, H.V. 11A2426 Sensor Temperature & Humidity 11A2427 Cable Temperature &...

  • Page 240: Toner (Used) Reservoir/ Hv

    Assembly 3: Toner (used) Reservoir/ HV...
  • Page 241 Asm- Part Index Number Units Description Bolt, PP 11A2340 11A2429 Cover, Conn. 11A2431 Panel, Guide 11A2432 Hinge Upper, Door 11A2433 Stopper Spring 11A2031 Cover, Switch Spring, PP 11A2354 11A2032 Size Sensor Asm, includes Ejection Sensor Board 11A2033 Switch, Main 11A2034 Sensor, Waste Toner Asm 11A2035 Button, Switch...

  • Page 242: Major Assemblies (Top/Bottom)

    Assembly 4: Major Assemblies (Top/Bottom)
  • Page 243 Asm- Part Index Number Units Description 11A2039 Stop, Left 11A2040 Cover, W/ Label 11A2041 Foot, Front 11A2042 Cover, Bottle Connector, 3P, PP 11A2389 Clamp, Cord, PP 11A2389 Clamp, PP 11A2389 Clip, PP 11A2389 Screw, PP 11A2331 11A2043 Cross-member Screw, PP 11A2331 11A2044 Latch, Roller Screw, PP 11A2340...

  • Page 244: Dc Controller / Video Controller Board

    Assembly 5: DC Controller / Video Controller Board 7-10...
  • Page 245 Asm- Part Index Number Units Description 11A2045 Holder, Cable 11A2046 Cover, Upper Plate 11A2047 Mount, DC Controller 11A2048 Mount, DC Controller 11A2049 Cover, DC Controller 11A2742 Ferrite Core (mounts to #5) 11A2050 Mount, DC Controller 11A2051 Cable 11A2052 Cable 11A2053 Cable 11A2054 Cable...

  • Page 246: Laser

    Assembly 6: Laser 7-12...
  • Page 247 Asm- Part Index Number Units Description Screw, PP 11A2331 11A2072 Printhead 11A2073 Holder, Sensor 11A2074 Stopper, Laser, PCB 11A2075 Cable, Toner Sensor 11A2076 Shutter, Laser 11A2077 Mount, Panel 11A2078 Bracket, Shutter Spring, PP 11A2354 Connector 3 Pin, PP 11A2389 Clip, Cable, PP 11A2389 11A2079 Rail, PC Cartridge Screw, PP 11A2331...

  • Page 248: Drive, Main

    Assembly 7: Drive, Main 7-14...
  • Page 249 Asm- Part Index Number Units Description 11A2087 Duct Fuser Fan Asm 11A2088 Duct, Upper Fan 11A2089 Duct, Lower Fan 11A2090 LVPS 110 V 11A2091 LVPS 220 V 11A2092 Motor, Main Drive 11A2093 Fan, Fuser 11A2094 Fan, DC Controller, Laser 11A2095 Gear, Cartridge Press Connector, Snap Tite, PP 11A2389 Connector, 5 Pin Male, PP 11A2389...

  • Page 250: Density Adjustment Panel

    Assembly 8: Density Adjustment Panel 7-16...
  • Page 251 Asm- Part Index Number Units Description 11A2112 Cover, Cleaning 11A2113 Stopper, Right Clamp, Cable, PP 11A2389 11A2114 Plate, Sensor 11A2115 Cable, Rotary Bushing, PP 11A2379 11A2116 Sensor, Photo 11A2117 IC TLP1230, Sensor Screw, W/Washer, PP 11A2340 11A2118 Holder, Contact 11A2119 Contact Screw, PP 11A2340 11A2120...

  • Page 252: Bottom Plate

    Assembly 9: Bottom Plate 7-18...
  • Page 253 Asm- Part Index Number Units Description 11A2128 Plate, Left, Slide Out 11A2129 Guide, Slide 11A2130 Shield, Conn. 11A2131 Rail, Cassette Rt 11A2132 Rail, Cassette Lft 11A2133 Crossmember Rail 11A2134 Foot, Front 11A2135 Grip, Front, Right 11A2136 Grip, Rear, Right 11A2137 Support, Rock Pin 11A2138 Plate, Right, Slide Out...

  • Page 254: Door Switch, Upper

    Assembly 10: Door Switch, Upper 7-20...
  • Page 255 Asm- Part Index Number Units Description 10-1 11A2141 Arm, Door 1 11A2142 Arm, Door 2 11A2143 Guide, Cable 11A2144 Mount, Switch Upper 11A2145 Cable, Control Spring, PP 11A2354 Screw, PP 11A2331 Screw, PP 11A2331 E-Ring, PP 11A2373 Parts Catalog 7-21...

  • Page 256: Door Switch, Lower

    Assembly 11: Door Switch, Lower 7-22...
  • Page 257 Asm- Part Index Number Units Description 11-1 11A2146 Arm, Rocker 11A2147 Plate, Insulating Switch 11A2148 Mount, Switch Lower 11A2149 Plate, Slide 11A2150 Cable, Switch 11A2151 Switch Spring, PP 11A2354 Screw, PP 11A2340 Spring, PP 11A2354 11A2152 Arm, Push Upper 11A2153 Arm, Push Lower E-RIng, PP 11A2373 Parts Catalog 7-23...

  • Page 258: Ejector Lever

    Assembly 12: Ejector Lever 7-24...
  • Page 259 Asm- Part Index Number Units Description 12-1 11A2740 Ejector Asm 11A2154 • Ejector 11A2155 • Guide 11A2156 • Hook 11A2157 • Oil Damper • Spring, PP 11A2354 Parts Catalog 7-25...

  • Page 260: Solenoid Plate

    Assembly 13: Solenoid Plate 7-26...
  • Page 261 Asm- Part Index Number Units Description 13-1 11A2158 Mount, Solenoid 11A2159 Cable 11A2160 Solenoid 11A2161 Solenoid Conn. 2 Pin, PP 11A2389 Conn. 3 Pin, PP 11A2389 Clip, PP 11A2389 Clip, PP 11A2389 Screw, PP 11A2331 Parts Catalog 7-27...

  • Page 262: Cleaning Belt Drive Solenoid

    Assembly 14: Cleaning Belt Drive Solenoid 7-28...
  • Page 263 Asm- Part Index Number Units Description 14-1 11A2162 Lever, Solenoid 11A2163 Mount, Solenoid 11A2164 Solenoid Conn. 2 Pin, PP 11A2389 E-Ring, PP 11A2373 Screw, PP 11A2340 Parts Catalog 7-29...

  • Page 264: Rotary Manual Feed

    Assembly 15: Rotary Manual Feed 7-30...
  • Page 265 Asm- Part Index Number Units Description 15-1 11A2165 Feeder, Rotary Manual Asm 11A2167 • Shaft 11A2166 • Hook, Lock Parts Catalog 7-31...

  • Page 266: Printer Drive

    Assembly 16: Printer Drive 7-32...
  • Page 267 Asm- Part Index Number Units Description 16-1 11A2168 Drive Asm complete 11A2169 • Toner Empty Sensor (Beam) 11A2170 • Bearing Asm, Rotary Unit 11A2171 • Bearing Asm, Transfer Drum 11A2172 • Clutch Asm, Fuser Drive 11A2173 • Motor Asm, Transfer Drum 11A2174 •...

  • Page 268: Transfer Drum Cleaning Drive

    Assembly 17: Transfer Drum Cleaning Drive 7-34...
  • Page 269 Asm- Part Index Number Units Description 17-1 11A2177 Transfer Drum Clean Drive Asm 11A2178 • Coupler Parts Catalog 7-35...

  • Page 270: Discharge Roller Drive

    Assembly 18: Discharge Roller Drive 7-36...
  • Page 271 Asm- Part Index Number Units Description 18-1 11A2179 Discharge Roller Drive Asm 11A2180 • Cam Parts Catalog 7-37...

  • Page 272: Drum Lift

    Assembly 19: Drum Lift 7-38...
  • Page 273 Asm- Part Index Number Units Description 19-1 11A2181 Drum Lift Asm 11A2182 • Cam Parts Catalog 7-39...

  • Page 274: Attraction Roller Drive

    Assembly 20: Attraction Roller Drive 7-40...
  • Page 275 Asm- Part Index Number Units Description 20-1 11A2183 Attraction Roller Drive Asm 11A2184 • Cam Parts Catalog 7-41...

  • Page 276: Paper Drive

    Assembly 21: Paper Drive 7-42...
  • Page 277 Asm- Part Index Number Units Description 21-1 11A2185 Delivery Drive Asm 11A2186 • Belt Parts Catalog 7-43...

  • Page 278: Universal Cassette

    Assembly 22: Universal Cassette 7-44...
  • Page 279 Asm- Part Index Number Units Description 22-1 11A2187 Lever, Release Lock 11A2188 Arm, Release 11A2189 Lever, Size 11A2190 Panel, Limit Rear 11A2191 Cover, Cassette 11A2192 Body Cassette 11A2193 Cam, Size 11A2194 Cover, Size 11A2195 Plate, Cam 11A2196 Button, Release 11A2197 Cover, Release 11A2198 Cap, Lifting...

  • Page 280: Paper Pickup

    Assembly 23: Paper Pickup 7-46...
  • Page 281 Asm- Part Index Number Units Description 23-1 11A2213 Cover, Motor 11A2214 Mount, Pivot Spring, PP 11A2364 Spring, PP 11A2364 Spring, PP 11A2364 Screw, PP 11A2331 Screw, PP 11A2331 11A2215 Cover See “Cassette Paper Pickup Asm” on page 7-48 See “Multipurpose Feeder Pickup Asm” on page 7-52 Parts Catalog 7-47...

  • Page 282: Cassette Paper Pickup Asm

    Assembly 24: Cassette Paper Pickup Asm 7-48...
  • Page 283 Asm- Part Index Number Units Description 24-1 11A2216 Cassette Paper Pickup Asm 11A2219 • Shaft Asm 11A2221 • Lever, Lock Slide 11A2223 • Roller, Asm Rear 11A2225 • Motor, Paper Pickup Asm 11A2226 • Solenoid 11A2227 • Clutch • Spring, Lever Lock, PP 11A2364 Parts Catalog 7-49...
  • Page 284 Assembly 24: Paper Pickup Cassette (cont.) 7-50...
  • Page 285 Asm- Part Index Number Units Description 24-1 11A2216 Cassette Paper Pickup Asm 11A2218 • Roller Asm 11A2220 • Roller 11A2222 • Guide Asm 11A2224 • Roller Asm 11A2228 • PCB Paper Pickup Asm Parts Catalog 7-51...

  • Page 286: Multipurpose Feeder Pickup Asm

    Assembly 25: Multipurpose Feeder Pickup Asm 7-52...
  • Page 287 Asm- Part Index Number Units Description 25-1 11A2217 Multipurpose Paper Pickup Asm 11A2229 • Clip, Roller 11A2230 • Roller, Pickup 11A2231 • Guide, Upper Asm 11A2232 • Pad, Main 11A2233 • Roller, U-turn Asm 11A2234 • Base Asm 11A2235 • Solenoid 11A2117 •...

  • Page 288: Paper, Side Exit Asm

    Assembly 26: Paper, Side Exit Asm 7-54...
  • Page 289 Asm- Part Index Number Units Description 26-1 11A2236 Delivery Asm 11A2237 • Frame Asm, Without Rollers 11A2117 • Sensor, Cleaning Belt Parts Catalog 7-55...

  • Page 290: Developing Rotary Asm

    Assembly 27: Developing Rotary Asm 7-56...
  • Page 291 Asm- Part Index Number Units Description 27-1 11A2238 Rotary Asm 11A2239 • Rotary Disc 11A2240 • Rotary Center Asm Parts Catalog 7-57...

  • Page 292: Transfer Drum Mounting Asm

    Assembly 28: Transfer Drum Mounting Asm 7-58...
  • Page 293 Asm- Part Index Number Units Description 28-1 11A2241 Transfer Drum Holder Asm 11A2243 • Slide, Front Asm 11A2244 • Contact, HV Asm 11A2245 • Slide, Rear Asm 11A2246 • Knob, Manual Asm 11A2242 • Lever, Operation • “Transfer Drum” on page 7-60 11A2415 Sheet, Transfer Drum 11A2703...

  • Page 294: Transfer Drum

    Assembly 29: Transfer Drum 7-60...
  • Page 295 Asm- Part Index Number Units Description 29-1 11A2247 Drum, Transfer Asm 11A2117 • Sensor 11A2700 •Solenoid 11A2702 •Claw, Separation 11A2709 •Arm, Sensing •Spring, PP 11A2354 11A2711 • Cover, Sensor 11A2712 • Cover, Sensor 11A2116 • Sensor 11A2454 •Roller, Discharge 11A2452 •Roller, Static Parts Catalog 7-61...
  • Page 296 Assembly 29: Transfer Drum (Cont.) 7-62...
  • Page 297 Asm- Part Index Number Units Description 29-1 11A2247 Drum, Transfer Asm 11A2248 • Gripper, Paper Asm 11A2117 • Sensor 11A2701 • Solenoid 11A2453 • Cap, Plastic Parts Catalog 7-63...

  • Page 298: Density Sensor Asm

    Assembly 30: Density Sensor Asm 7-64...
  • Page 299 Asm- Part Index Number Units Description 30-1 11A2249 Support, Corona 11A2250 Link 11A2251 Plate Sen/Sep 11A2252 Plate, Sensor 11A2253 Corona, Separation Asm 11A2254 Sensor, Density Spring, PP 11A2364 Screw, PP 11A2340 Screw, PP 11A2331 11A2255 Cover 11A2256 Cable E-Ring, PP 11A2373 E-Ring, PP 11A2373 Parts Catalog 7-65...

  • Page 300: Transfer Drum Cleaning

    Assembly 31: Transfer Drum Cleaning 7-66...
  • Page 301 Asm- Part Index Number Units Description 31-1 11A2257 Transfer Drum Clean Asm 11A2259 • Motor 11A2258 • Brush 11A2732 • Blade Parts Catalog 7-67...

  • Page 302: Fuser

    Assembly 32: Fuser 7-68...
  • Page 303 Asm- Part Index Number Units Description 32-1 11A2260 Fuser 110 V Asm 11A2267 • Oil Tray Asm 11A2270 • Fuser Oil Apply Asm 11A2271 • Fuser Cleaner Asm 11A2261 • Fuser Asm 220 V 11A2266 • Thermistor 11A2733 • Cover Asm 11A2117 •...

  • Page 304: Fuser

    Assembly 32: Fuser Asm (Cont.) 7-70...
  • Page 305 Asm- Part Index Number Units Description 32-1 11A2260 Fuser Asm 110 V 11A2268 • Lamp 110 V 11A2265 • Oil Applying Input Asm 11A2273 • Fuser Delivery Asm 11A2274 • Oil Bottle Case Asm 11A2261 Fuser 220 V Asm 11A2269 •...

  • Page 306: Video Controller Board

    Assembly 33: Video Controller Board 7-72...
  • Page 307 Asm- Part Index Number Units Description 33-1 69G3802 Video Controller Board 69G3790 ROM SIMM 1342514 Line Cord (US) 1342536 Line Cord (APG-ARG) 1342543 Line Cord (UK) 1342530 Line Cord (Europe) 1342537 Line Cord (Israel) 1342533 Line Cord (Switzerland) 1342532 Line Cord (South Africa) 1342534 Line Cord (Italy) 1342535...

  • Page 308: Optional Paper Feeder (Main Body)

    Assembly 34: Optional Paper Feeder (Main Body) 7-74...
  • Page 309 Asm- Part Index Number Units Description 34-1 11A2277 Lock Lever Link 11A2286 Link 11A2278 Left Cover 11A2279 Right Cover 11A2280 Front Cover 11A2281 Rear Cover 11A2282 Cover, Open/Close 11A2283 Gear Cover 11A2284 Hinge, Cover Right 11A2285 Hinge, Cover Left 11A2287 Switch Rod Plate Screw, PP 11A2331 Screw, PP 11A2331...

  • Page 310: Optional Paper Feeder (Front)

    Assembly 35: Optional Paper Feeder (Front) 7-76...
  • Page 311 Asm- Part Index Number Units Description 35-1 11A2218 Roller Assembly 11A2289 Spring Collar 11A2291 Plate 11A2292 Crossmember 11A2293 Motor Mount 11A2294 Paper Feed Roller 11A2295 Front Drive Roller Shaft 11A2296 Pickup Roller Shaft 11A2297 Release Roller 11A2298 Upper Paper Guide 11A2299 Sensor Arm 11A2300...
  • Page 312 Assembly 35: Optional Paper Feeder (Front)(Cont.) 7-78...
  • Page 313 Asm- Part Index Number Units Description 35-23 Gear, PP 11A2402 Gear, PP 11A2402 Gear, PP 11A2402 Gear, PP 11A2402 Gear, PP 11A2402 Gear, PP 11A2402 Gear, PP 11A2402 Gear, PP 11A2402 Gear, PP 11A2402 Gear, PP 11A2402 Gear, PP 11A2402 Spring , PP 11A2364 11A2117...

  • Page 314: Paper Pickup Asm (Base)

    Assembly 36: Paper Pickup Asm (Base) 7-80...
  • Page 315 Asm- Part Index Number Units Description 36-1 11A2308 Paper Pickup Asm Base 11A2309 • Cassette Size Sensor Asm 11A2310 • Cable 11A2311 • Power Supply Cable 11A2312 • Power Supply PCB 11A2414 • Paper Feed PCB Parts Catalog 7-81...

  • Page 316: Paper Pickup Asm (Rear)

    Assembly 37: Paper Pickup Asm (Rear) 7-82...
  • Page 317 Asm- Part Index Number Units Description 37-1 11A2313 Paper Pickup Asm Rear 11A2314 • Lock Lever, Right 11A2315 • Lock Lever, Left 11A2316 • Rear Roller Asm 11A2317 • Roller 11A2318 • Roller Holder • Spring, PP 11A2364 • Latch Spring, PP 11A2364 •...

  • Page 318: Options

    Assembly 38: Options Asm- Part Index Number Units Description 1364921 Memory SIMM 2MB 1364877 Memory SIMM 4MB 1364876 Memory SIMM 8MB * 1364875 Memory SIMM 16MB 1364874 Memory SIMM 32MB 1364923 Flash Memory 1MB 1364922 Flash Memory 2MB 1364879 Flash Memory 4MB 1364873 Hard Drive 40MB 1381856...
  • Page 319 5045-001 Parts Catalog 7-85...

  • Page 321: Index

    5045-001 Index Diagnostic Aids Basic Engine Test Abbreviations Diagnostics Mode Adjustments Diagnostics Mode Menu Density Adjustment Panel Diagnostic Approach Attraction Roller Drive Diagnostic Information Diagnostics Mode Diagram, wiring Blank Page 2-61 Dirt On Back Of Paper 2-65 Button Test Discharge Roller Drive 4-25 Disk Test/Clean Distortion...
  • Page 322 5045-001 Error Codes (continued) 146 Communication 2-27 Hardware Tests 147 Engine Board 2-27 High Voltage Converter 4-40 148 Developer Rotation 2-28 High Voltage Power Supply 4-40 149 Developer Pressure 2-29 Horizontal Voids 2-67 152 Tray 2 Power Failure 2-29 HV Power Supply Output 2-33 46 Cartridge Installation 2-14...
  • Page 323 5045-001 Parts Catalog PCBs 5-11 Page Count Permanent Page Count Page Count Tests Pickup / Feed System Theory 2-34 Paper Delivery Asm 4-44 Pickup Roller(s) 4-67 Paper Feed Roller (Unit 2) 4-66 Pickup Sensor 4-67 Paper Feed Troubleshooting 2-38 Poor Fusing 2-69 Paper Pickup Motor 4-66...
  • Page 324 5045-001 Multipurpose Feeder D-Roll Solenoid 4-43 Rear Cooling Duct 4-50 D-Roller 4-42 Rear Cooling Fan 4-49 Paper Pickup 4-42 Registration Roller Paper Sensor 4-42 Does Not Rotate 2-33 U-Turn Roller 4-43 Registration Roller Drive Clutch Optional Paper Feeder 4-64 Removals Cassette Sensing Bd 4-64 Attraction Roller Drive...
  • Page 325 5045-001 Print Quality 2-50 2-61 Black 2-61 Safety Inspection Guide Blank Page 2-62 Screws Blank Spots 2-63 Sensors Color Aberration 2-63 Service Checks Dark Image 2-64 Cartridge Installation 2-14 Dirt On Back Of Paper 2-65 Communication Failure 2-27 Dirty Print 2-66 Controller Fan Motor 2-23...
  • Page 326 5045-001 Tests Upper Cooling Fan 4-63 Button Test Upper Output Drive Asm 4-63 Compressor Defaults Density Adjustment Panel 3-12 Vertical Lines 2-72 Disk Test/Clean Vertical Voids 2-73 Error Log Video Controller Board 4-63 Flash Test LAN Information 3-21 LCD Test Wiring diagram Memory Wrap Tests...

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