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Lexmark Optra Color 1200 Service Manual

Service manual
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Optra Color 1200
5050-001
• 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 Color 1200

  • Page 1 Optra Color 1200 5050-001 • 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 D22/035-3, 740 New Circle Road N.W., 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

    5050-001 Contents Safety Information........ix Safety Notice .
  • Page 4 5050-001 Transport Belt/BUD Service Check ..... . .2-30 Optional Paper Feed Service Check ..... .2-31 Paper Jam Service Check .
  • Page 5 5050-001 Test Print 1......... 3-28 Test Print 2.
  • Page 6 5050-001 Power Supply Switch Removal ......4-46 Power Supply Board (P614-MPS) Removal ....4-47 Size Sensor Board (P611-PSZ) Removal .
  • Page 7 5050-001 Assembly 2: Paper Exit ........7-6 Assembly 3: Upper Unit .
  • Page 8 5050-001 viii Service Manual...

  • Page 9: 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 10 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 11 Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição. • As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser...
  • Page 12 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 13 5050-001 xiii Safety Information...
  • Page 14 5050-001 Service Manual...

  • Page 15: General Information

    5050-001 1. General Information 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, and service checks to determine the symptom and repair the failure. You may find that the removals in the Repair Information chapter will help you identify parts.

  • Page 16: Serial Number

    5050-001 Serial Number Lower the multipurpose feeder and refer to the label on the right. The serial number is also listed on the menu settings page you can print from the Tests Menu. Service Manual...

  • Page 17: Abbreviations

    5050-001 Abbreviations ASIC Application-Specific Integrated Circuit Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically 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 18: Standard Features

    5050-001 Standard Features Print method Dry electrophotographic process using LED printheads Print 600 dpi addressability Maximum print • 12 ppm (letter and A4 paper) (Color) speed • 12 ppm (Mono) Fonts 1. 75 resident scalable fonts: • PostScript Level 2 emulation: 39 Optra compatible plus 36 additional •...

  • Page 19: Options

    • Maximum installed memory: 128MB Hard disk option 2.5-inch hard disk to store fonts, forms, job statistics, and spooled jobs Hard disk For installing compatible Lexmark or third-party hard adapter ribbon disks cable MarkNet S Adapters available to support the following topologies:...

  • Page 20: Printer Supplies

    5050-001 Printer Supplies Toner cartridges Black, magenta, cyan, or yellow 6,500 pages each cartridges (5% coverage) Photoconductors • Black photoconductor (with fuser 13,000 pages each coating roll) • Cyan, magenta, and yellow photoconductors (packaged together) Transparencies A4 and letter size Cross Section of Printer Fuser Roller Absorption Roller...
  • Page 21 5050-001 General Information...

  • Page 22: Operational Theory

    5050-001 Operational Theory This printer makes a color image by overlapping each color toner in dot units and fusing them to the paper. The process is divided into two steps. The first step is the electrophotographic process which forms the image on the PC. The second step consists of Feeding, Transferring, Fusing which feeds the paper, transfers the image to the paper and fuses the toner.
  • Page 23 5050-001 General Information...

  • Page 24: Photoconductor Drum

    5050-001 Photoconductor Drum The photoconductor drum uses aluminum as the base material and a layer of organic photo conductor (OPC) on the surface. A characteristic of this layer is that only the part that the light shines on becomes conductive. Electrical Charge Unit The charge roller of the electrical charge unit evenly charges the surface of the drum.

  • Page 25: Exposure Assembly

    5050-001 Exposure Assembly The exposure assembly uses an LED head to form an electrostatic image by emitting light onto the charged drum. The length of time the light is on is contained in non-volatile memory (EEPROM) in the printer controller because the light emitting time of each LED is different in every head.

  • Page 26: Transfer Assembly

    5050-001 Transfer Assembly Paper is held to the transfer belt electrostatically. The belt rotates at the same speed as the photoconductor drum. The absorption roller applies a positive charge to the paper. The toner formed on the photoconductor drum transfers to the paper because of the positive charge from the transfer sheet under the transfer belt.

  • Page 27: Cleaning Assembly

    5050-001 Cleaning Assembly The cleaning blade scrapes off the remaining toner on the photoconductor drum after the toner image has been transferred to the paper. A rotating coil in the waste toner conveyance assembly conveys the scraped-off toner to the waste toner bag. 1-13 General Information...

  • Page 28: Paper Feed, Transfer, And Fusing

    5050-001 Paper Feed, Transfer, and Fusing Two drives perform the entire paper feed in this printer, drive 1 and drive 2. There is a separate motor in the second paper feeder to drive the paper feed. Drive 1 Drive 1 consists of a brush-less dc motor and gear unit. Drive 1 carries paper from the paper feed unit to the registration unit and also drives the electrophotographic process.
  • Page 29 5050-001 1-15 General Information...
  • Page 30 5050-001 Paper Cassette Feeder The printer controller sends a signal to the paper feed solenoid which turns on and drives the paper feed roller connected to drive 1 by a spring clutch. The paper in the cassette is picked one sheet at a time.
  • Page 31 5050-001 Registration Paper feed stops temporarily at the registration roller to make the top edge of the paper parallel to the photosensitive drum and to adjust feed timing with the toner image on the photosensitive drum. In parallel to the photosensitive drum, the rubber registration roller presses against the metal registration upper roller.
  • Page 32 5050-001 Separation Assembly The paper separates from the transfer belt at the drive roller section of the belt assembly. The electric charge on the paper is then eliminated by the discharge brush. 1-18 Service Manual...
  • Page 33 5050-001 Fuser Assembly The press roller presses the paper with toner against the heated fuser roller which fuses and fixes the toner to the paper. The separator pawl separates the paper from the fuser roller. Exit Unit The fused paper is ejected from the printer. The exit sensor checks the state of the paper, while the flap performs the change-over of paper exit direction (face down, face up).
  • Page 34 5050-001 When automatic switching is set (default), the face up/face down (FUD) solenoid is turned on by a signal from the printer controller and the spring clutch transfers power from the exit roller to the flap. The flap is then switched by a cam mechanism on the exit roller. 1-20 Service Manual...
  • Page 35 5050-001 Transfer Belt The positive-charged absorption roller charges the paper as it enters the transfer belt. The belt rotates at the same speed as the photoconductor drum.Toner is transferred to the paper in the order of magenta, cyan, yellow, and black. As the paper passes each photoconductor drum, the static from the transfer belt pulls toner away from the drum.
  • Page 36 5050-001 1-22 General Information...
  • Page 37 5050-001 Belt Up or Down (BUD) During monochrome printing, only the black transfer and development functions operate. An electromagnetic clutch in drive 1 operates to pull the transfer belt down as the paper passes under the color PC drums. A cam on the changing shaft moves the belt up and down through gears from the belt unit drive motor on the unit frame.
  • Page 38 5050-001 1-24 General Information...
  • Page 39 5050-001 Paper Path for Mono Pages Paper Path for Color Pages 1-25 General Information...

  • Page 40: Print Modes

    5050-001 Second Paper Feed Up to two additional paper feeders can be used under this printer. The operation of the optional paper feeder is the same as the base printer cassette feeder except the optional paper feeder has its own motor to drive paper to the printer paper path.

  • Page 41: Clearing Paper Jams

    5050-001 Processing speed is reduced 75% in OHP mode. The fuser temperature is set at 20 degrees higher than normal printing. This is to improve the smoothness of the toner image by ensuring the toner melts enough in the fuser. When you load transparencies in the multipurpose feeder, the printer recognizes this type of media you have loaded and automatically makes these adjustments.

  • Page 42: Printing From The Multipurpose Feeder

    5050-001 When clearing a jam, open the top cover completely and clear all paper from the entire paper path. Make sure you also clear paper jammed in the paper tray. Close the top cover and press The following table lists the paper jam messages. 200 Paper Jam Open Top Cover 201 Paper Jam...

  • Page 43: Diagnostic Information

    5050-001 2. Diagnostic Information The diagnostic information in this chapter leads you to the failing part. Before you replace an entire assembly, determine if just the defective part is available in the parts catalog. Use the error code tables, symptom table, service checks and the diagnostic aids chapter to determine the symptom and repair the failure.

  • Page 44: Start

    5050-001 Printer Controller Board/Printer Control EEPROM (U107) If you replace the printer controller board, remove EEPROM (U/107) and install it on the new board. Also check the printhead adjustment. If you change the EEPROM, the following items must be checked and adjusted in the service mode.

  • Page 45: Printer Messages

    5050-001 Installation Environment • The power supply line voltage is plus or minus 10% of the rated line voltage. • The machine is securely installed on a level surface in a well- ventilated place. • The room temperature is between 10 and 32°C (50 and 90°F) and the relative humidity between 20 and 80%.

  • Page 46: Service Error Message Table

    5050-001 Service Error Message Table Message Software Error Unrecoverable software error. Refer to the operator manual. Motor Error 1. Be sure motor connector CN501 is connected properly to the PC DC Drive 1 Motor Failure motor drive (1). 2. Be sure printer controller board connector CN105 is connected properly.
  • Page 47 5050-001 Message Fuser Error 1. Remove the fuser heater cable from the power supply (CN602) Fuser Heater Trouble and check it for continuity. If there is no continuity in the heater wire, replace the fuser heater and the fuser oil coating roller. If there is no continuity in the thermostat, or it does not equal 240K Ohms at 25 degrees C (room temperature),...
  • Page 48 5050-001 Message Font ROM Error Replace the EEPROM code controller, solid state drive (J10) (11G0607) on the RIP control card. RIP Controller Board, Font The font and RIP controller card Error (11G0604) are incompatible. RIP Controller Card Error Replace the RIP controller card (11G0604).
  • Page 49 5050-001 Message Network Card Error The system processor has detected an INA is installed but cannot communicate with it. The X after the card indicates which one has the problem. Network card 1 always refers to the INA in the bottom slot and Network card 2 always refers to the INA in the top slot.
  • Page 50 5050-001 Message Gear Sensor 1. Be sure CN123 and CN126 are properly connected to the printer Abnormal Gear Sensor controller board. (Color/Black) 2. Clean the gear/drum sensor. 3. Replace the drum drive gear sensor 11G0581). If you still have the problem, go to “Drive 1 DC Motor Service Check”...
  • Page 51 5050-001 Message Engine Error 1. Be sure connector CN121 is properly connected to the printer Abnormal Humidity Sensor controller board. Also be sure the connector on the humidity sensor card is plugged in correctly. 2. Replace the humidity sensor (11G0571). 3.

  • Page 52: Status Messages

    5050-001 Status Messages Ready The printer is ready to receive and process data. Power Saver When your printer is in power saver mode, the Power message replaces the message on the Saver Ready display. When is displayed, your printer is Power Saver ready to receive and process data.
  • Page 53 5050-001 Ready Hex Hex Trace diagnostic mode is active, and the printer is ready to receive data. Use Hex Trace to isolate the source of a print job problem. With Hex Trace selected, all data sent to the printer is printed in hexadecimal and character representation.
  • Page 54 5050-001 Cancelling Job The printer is processing a request to cancel the print job. Resetting the The printer is deleting any print jobs in progress and Printer restoring all print settings to the user defaults. Flushing Buffer The printer is flushing corrupted print data and discarding the current print job.

  • Page 55: Attendance Messages

    5050-001 Programming Disk The printer is storing resources on the hard disk. Do not turn the printer off while this message is displayed. The network adapter is being reset. The Network x Network Card Busy Setup menu is not available while this message is displayed.
  • Page 56 5050-001 Load tray The printer is trying to feed paper from a source it detects is empty (tray 1, 2, 3, or the multipurpose feeder). The message displays either the custom media name defined using the MarkVision utility, the media size, or the media size and type it is looking for. To clear the message: •...
  • Page 57 5050-001 Print Jobs on Disk? Jobs that were spooled to the optional hard disk before the printer was last turned off have not yet printed. Press to print the jobs. Press Return Stop delete the jobs from the disk without printing them. Files Will be Lost.
  • Page 58 5050-001 37 Insufficient The printer memory (or optional hard disk, if installed) Collation Area does not have the space necessary to collate the print job. • Press to print the portion of the job already stored and begin collating the rest of the job. •...
  • Page 59 5050-001 52 Flash Full There is not enough space available to hold the resources you want to store in flash memory. • Press to clear the message and continue processing. Downloaded fonts and macros not previously stored in flash memory or disk are deleted.
  • Page 60 5050-001 54 Serial Option x The printer has detected a protocol error on the Error specified serial interface. Make sure the serial interface parameters are set up correctly and you are using an appropriate serial cable. • Press to clear the message and continue printing.
  • Page 61 5050-001 56 Parallel Port x Data was sent to the specified parallel port, but the Disabled port has been disabled from the Parallel Buffer menu item. • Press to clear the message. The printer discards the data sent to the parallel port. •...
  • Page 62 These items are in a maintenance kit available from Lexmark. You must have a trained service technician install the maintenance kit.
  • Page 63 5050-001 84 Color PC Life This message alerts you that you can print Warning approximately 100 pages before the Color PC Drums message appears. If you do not have new Exhausted color photoconductors, order them now. The cyan, magenta, and yellow photoconductors come packaged together.
  • Page 64 5050-001 84 Color PC Drums The three color photoconductors have reached the Exhausted end of their 13,000-page life. You may want to replace the photoconductors now. When you do replace them, replace all three—cyan, magenta, and yellow—at the same time. If the print quality is still acceptable, press to clear the message and continue printing.

  • Page 65: Symptom Table

    Go to the “Transport Belt/BUD Service Check” on page 2-29. Transparencies curl Make sure you’re using the recommended excessively. Lexmark transparencies. Also be sure the paper delivery is set to the rear exit. 2-23 Diagnostic Information...
  • Page 66 5050-001 Transparencies jam If the last transparency jams as you try to feed it from tray 1, place the cardboard sheet (with the cutout) included in the transparencies box in the bottom of tray 1 before loading transparencies. The printer seems If you set Print Quality to 1200 Image Quality, it slow to print may take longer to print some complex jobs or jobs...
  • Page 67 5050-001 Paper jam in pick-up Go to the “Paper Carrying Service Check” on assembly page 2-32. Fuser failure Go to the “Fuser Service Check” on page 2-27. No paper pick-up from Go the “Paper Carrying Service Check” on multipurpose tray page 2-32.
  • Page 68 5050-001 Evenly spaced marks Go to the “Marks on Paper Service Check” on on the paper, or a page 2-37. single mark in the same place on every page. Poor fusing Go to the “Fuser Service Check” on page 2-27. Toner scatter on front Check the following: or back of paper...

  • Page 69: Service Checks

    5050-001 Service Checks Fuser Service Check When you work on the fuser be sure to reposition it to the original mounting position. Also be sure the exit sensor and FUD sensors are not damaged when you replace the fuser. • Fuser The fuser may not be fusing correctly or not fusing Heater at all.

  • Page 70: Color Print Unit Missing Service Check

    5050-001 Color Print Unit Missing Service Check When you replace the PC drum unit, all three color units must be replaced at the same time. Color Print Check for dirt or damage to the sensing contacts on Unit the right side of the cartridge assembly. Clean or replace the PC drum unit if necessary.

  • Page 71: Drive 2 Stepper Motor Service Check

    5050-001 Drive 2 Stepper Motor Service Check Drive 2 Be sure connector C112 on the printer controller Stepper Motor board is firmly connected. If you still have the problem, replace the drive 2 stepper motor (11G0260). Drive 2 If the drive 2 stepper motor rotates and the fuser, Stepper Motor and exit rolls do not rotate, replace the drive 2 Unit...

  • Page 72: Optional Paper Feed Service Check

    5050-001 Optional Paper Feed Service Check If you have a 24XX error code, the last number in the code indicates the affected tray. Check the option connection cable for proper connection to the printer or other paper feeder. If you have two optional feeders, you can connect the non-working one directly to the printer to check for a cable or drive card problem.
  • Page 73 5050-001 Service Check” on page 2-32. If it does not work properly, replace the actuator or sensor. If that doesn’t correct the problem, replace the printer controller board. Jam 201 Remove the cartridges. Check the registration sensor and the paper exit sensor.

  • Page 74: Paper Carrying Service Check

    5050-001 Paper Carrying Service Check The paper is being picked up and carried to the registration roll. • Paper Size Be sure the paper cassette has the size guides and Guide the side locator locks are working properly. • Side Location Replace parts as necessary.
  • Page 75 5050-001 The paper has stopped at the registration roller or has not reached the fuser. If the fuser or exit rollers do not turn during POR, go to the “Drive 2 Stepper Motor Service Check” on page 2-29. • Registration Check these parts for wear or damage.

  • Page 76: Paper Exit Fu/Fd Service Check

    5050-001 The paper has exited the registration roll and entered the fuser. • Transfer Belt Remove any buildup of toner. Replace and Unit damaged or worn parts. • Rear Paper Guide • Discharge Brush • Fuser Roller • Fuser Press Roller Fuser Be sure the separation pawls do not have any toner...

  • Page 77: Paper Low/Empty Tray 1, 2, 3 Service Check

    5050-001 Flap Check the paper flap (vane) that directs the paper to the proper tray. Replace if necessary. FU/FD Check the FU/FD solenoid for continuity. Also be Solenoid sure connector CN122 is properly connected to the printer controller board. • Gear Check the gears and the metal actuating cam for •...

  • Page 78: Remove Paper Sensor Service Check

    5050-001 Remove Paper Sensor Service Check Remove Paper Check the operation of the paper full lever and Lever actuator shaft. Replace as necessary. Paper Full Check the sensor for operation. Check for Sensor approximately +5 V from CN109 pin 2 to GND when the sensor is activated.

  • Page 79: Marks On Paper Service Check

    5050-001 Marks on Paper Service Check If you have evenly spaced marks on the paper, measure the distance between the marks and locate the symptom below. Check the assembly for dirt or damage and clean as necessary. Run a test print to verify the problem has been corrected.

  • Page 80: Image Quality Troubleshooting

    5050-001 Image Quality Troubleshooting Print Quality Problems Print is too light, or printed Be sure you’re using recommended images or characters have voids paper or other media. Use media from a or dropouts. new package. Be sure you have selected the correct Paper Type setting for the media you’re using.
  • Page 81 5050-001 Toner specks appear on the Replace the fuser coating roll. If it is not page. time to order a black photoconductor kit, which includes a fuser coating roll, order a separate fuser coating roll (P/N 12A1706). Toner colors the background of Be sure the affected print unit is the page.
  • Page 82 5050-001 Light lines or streaks appear on Clean the LEDs. the printed page. Make sure the affected print unit is completely installed in the printer. Remove the affected print unit and gently shake it back-and-forth to distribute the toner evenly. Reinsert the print unit and try printing the job again.
  • Page 83 “Periodic Dirt” on page 2-44. Quality of printed transparencies Be sure you’re using the recommended is inadequate. Lexmark transparencies. Be sure you’re loading transparencies properly. When printing transparencies, always set the Paper Type to Transparency. Set the Color Correction menu item to Vivid.
  • Page 84 5050-001 No Image Moist Paper Be sure the printer is not in a damp environment and the paper is not curled or wavy due to moisture. If necessary inform the customer about correct storage. LED Head Be sure the LED head cable is securely connected to the head controller board and LED head assembly.
  • Page 85 5050-001 Black Print High Voltage Unit 1 The printed paper has black print. Be sure the high voltage unit 1 is prop- erly connected. If you still have a problem, replace the high voltage unit 1 (11G0326). Right Sub-frame If you still have the problem, replace the right sub-frame contacts.
  • Page 86 5050-001 High Voltage Unit 1 If you still have the problem, replace the high voltage unit 1 (11G0326). Transfer Belt Unit If you still have the problem, replace the transfer belt unit (11G0202). Partial Darkness or Lightness Photoconductor Drum Unit Check the PC drum for exposure to strong light.

  • Page 87: Sensor Service Check

    5050-001 Photoconductor Drum Check for scratches on the surface and replace if necessary. White Spots Condensation Check the LED head and photoconductor drum surface for condensation. Let it dry naturally. Printhead Unit Firmly install the PC drum unit into DS/TS the toner cartridge and the print unit into the printer.
  • Page 88 5050-001 6. If this does not correct the problem, replace the printer controller board. 7. If both the sensor and actuator are working correctly, replace the indicated part in the service check you were working in. 2-46 Service Manual...

  • Page 89: Diagnostic Aids

    5050-001 3. Diagnostic Aids Note: When trouble shooting, or prior to making any adustment to print quality, always be sure of the following: • The printer is installed on a level rigid surface. • The OPCs are never exchanged. Do not exchange a black OPC for a color OPC, as they will have different surface phase counts.

  • Page 90: Using The Operator Panel

    5050-001 Using the Operator Panel The operator panel on your printer has a 2-line by 16-character liquid crystal display (LCD), five buttons, and one indicator light. The light indicates whether the printer power is on and whether the printer is idle or busy processing a job. Indicator Light Printer power is off.

  • Page 91: Operator Panel Buttons

    5050-001 Operator Panel Buttons Press the button to: • Exit printer menus and return the printer to the ready state • Clear certain messages from the display If you’ve changed printer settings from the operator panel menus, press Go before you send a job to print. Menu >...

  • Page 92: Printing The Menu Settings

    5050-001 Printing the Menu Settings 1. From the printer operator panel, press the Menu> <Menu button to enter the menus. 2. Continue to press and release until you see Menu> <Menu TESTS MENU 3. Press the button. is then displayed on the Select TESTS MENU first line, and...
  • Page 93 5050-001 JOB MENU SETUP MENU PCL EMUL MENU Cancel Job Printer Language Font Source Reset Printer Power Saver Font Name Print Buffer Resource Save Point Size Download Target Pitch Print Timeout Symbol Set Wait Timeout Orientation Auto Continue Lines per Page Jam Recovery A4 Width Page Protect...

  • Page 94: Diagnostic Mode

    5050-001 NETWORK MENU INFRARED MENU LOCALTALK MENU NETWORK OPTION 1 Infrared Port LocalTalk Port NETWORK OPTION 2 PCL SmartSwitch PCL SmartSwitch PCL SmartSwitch PS SmartSwitch PS SmartSwitch PS SmartSwitch NPA Mode NPA Mode NPA Mode Infrared Buffer LocalTalk Buffer Network Buffer Job Buffering Job Buffering Job Buffering...
  • Page 95 5050-001 Tray 2 Test Test Tray 3 =-16 to 15 (0) Tray 3 Test Test MP Feeder =-16 to 15 (0) MP Feeder Test K TOP MAR ADJ Tray 1 =-16 to 15 (0) Tray 1 Test Test Tray 2 =-16 to 15 (0) Tray 2 Test Test...
  • Page 96 5050-001 Tray 2, if installed = Single = Continuous Tray 3, if installed = Single = Continuous MP Feeder = Single = Continuous Top Output = Single = Continuous Back Output = Single = Continuous Prt Quality Pgs = Single = Continuous HARDWARE TESTS LCD Test...
  • Page 97 5050-001 LIGHT QUANTITY • Cyan • Magenta • Yellow • Black 0 to 45 (0) Thermistor Rank 0 to 4 (0) Transfer Belt Adj 30 - Seconds Sensor Cal. • Paper • Transparency Cyan Drum Cnt 0 to 65535 Magenta Drum Cnt 0 to 65535 Yellow Drum Cnt 0 to 65535...

  • Page 98: Setting Printer Top Margin

    5050-001 Reset 80 Maint = Yes = No ERROR LOG Display Log Clear Log US/Non US Defaults • US • Non US EXIT DIAGNOSTICS “Exiting Diagnostics Mode” on page 3-27. Setting Printer top Margin The purpose of this function is to adjust the leading edge margin for each tray.

  • Page 99: Quick Test

    5050-001 To verify the margin values are correct, you must print the Quick Test page. From the Tray X test screen press Select. While the page is printing the following message is displayed. The Power indicator also blinks while the page is printing. Quick Test Printing...
  • Page 100 5050-001 To make this adjustment: Note: Before adjusting the margins, be sure the printer is set to the graphic print mode in the Print Quality Menu. The Print Quality Menu is a sub menu of the Color Menu. 1. Select the Diagnostic Mode. 2.

  • Page 101: Color Calibration Of Printer

    5050-001 Color Calibration of Printer Printhead Adjustment - X, Y, and Theta Test Print Pages Printing the color calibration pages allows a service person to align the Cyan, Magenta, and Yellow planes with the Black plane. The planes must be adjusted in three different directions, the X direction, the Y direction and the Theta direction.
  • Page 102 5050-001 Theta Position Adjustment (Alignment of the curve of the horizontal position over the length of the line) Modification of this setting allows the users to adjust the color offset of a color image for the line direction and page direction (X and Y). Changing this parameter by 1 unit moves the image 1 dot unit.

  • Page 103: Print Tests

    5050-001 Thermistor Rank If you replace the transfer belt unit or the EEPROM for the engine controller, the Thermistor rank value must be set according to the color of the lead line color. To set this value: 1. Select Diagnostic Mode. 2.

  • Page 104: Print Quality Pages

    5050-001 • Continuous (continue printing Print Test pages until Return or Stop is pressed). The first page Print Test contains seven vertical columns of black, cyan, magenta, yellow, red, green, and blue. The columns are shaded from 0% to 100% coverage. The second page contains a matrix of blocks outlined in primary colors which are used to show vertical and horizontal misalignment.

  • Page 105: Lcd Hardware Test

    5050-001 Once started, this operation cannot be cancelled. Furthermore, all key presses are ignored while this message is posted. LCD Hardware Test Selecting this test will cause the printer to continually execute the LCD display test. To cancel the test, press Return or Stop. Button Test The Button Test is used to verify the operation of each button on the operator panel.

  • Page 106: Std Parallel Wrap Test And Parallel X Wrap Test

    5050-001 F:##### represents the number of times the memory test has failed (finished with errors). Initially 00000 is displayed for #####. The maximum fail count is 99,999. The power indicator blinks indicating the memory test is in process. The printer continually runs the same test until cancelled from the control panel (by pressing Return or Stop).

  • Page 107: Serial Wrap Tests

    5050-001 F:##### represents the number of times the test has failed (finished with errors). Initially 00000 is displayed for #####. The maximum fail count is 99,999. The power indicator blinks indicating the test is in process. The printer continually runs the same test until cancelled from the control panel (by pressing Return or Stop).

  • Page 108: Quick Disk Test

    5050-001 P:###### represents the number of times the test has passed (finished successfully). Initially 000000 is displayed for ######. The maximum pass count is 999,999. F:##### represents the number of times the test has failed (finished with errors). Initially 00000 is displayed for #####. The maximum fail count is 99,999.

  • Page 109: Disk Test/Clean

    5050-001 If the test fails, the Power indicator is turned on solid and the following message is displayed. Press Go, Return, or Stop to return to the DEVICE TESTS screen. Quick Disk Test Test Failed Disk Test/Clean This test causes the file system to scan the disk for bad sectors and remove these blocks from the addressable space.
  • Page 110 5050-001 complete and number of bad blocks which have been found. The Power indicator also blinks while the cleaning phase is in progress. Cleaning Disk... Bad:000000 00% When the cleaning phase of the test is complete, the following screen is displayed to indicate the testing phase of the test has begun.

  • Page 111: Setting The Page Count

    5050-001 blocks exist on the disk. Press Go, Return, or Stop to return to the DEVICE TESTS screen. xxxxx Bad Blocks Replace Disk If the bad block count is 6 digits long (i.e. the whole disk is bad), then the ‘s’ is dropped from “blocks” to make room for the sixth digit. Setting the Page Count The printer’s page count can be changed via the Diagnostics menus.

  • Page 112: Viewing And Resetting The Drum Counters

    5050-001 Viewing and Resetting the Drum Counters The drum counters increment when a page is printed. The drum counter for a particular plane only increments if that color is printed. It increments by 1 for Letter, A4, A5, B5 and envelopes. It increments by 1.2 for Legal and B4.

  • Page 113: Viewing The Error Log

    5050-001 After the user selects Paper, the printer requests that paper be loaded. The paper must be loaded into the MP Feeder. Sensor Cal Insert Paper Press Go for the calibration to begin. The operator panel displays that it is performing the calibration. Sensor Cal.

  • Page 114: Clearing The Error Log

    5050-001 The following error messages are stored in the error log: All 2xx paper jam messages. All 9xx service messages. To view the error log, select the Display Log operation from the Diagnostics ERROR LOG menu. The entire error log cannot be displayed on a single screen.

  • Page 115: Us / Non-Us

    5050-001 Select No to exit the Clear Log menu. Pressing Return or Stop also exits the Clear Log menu. US / Non-US This setting is used by the printer to determine whether US /Non-US factory defaults should be selected. Exiting Diagnostics Mode To exit diagnostics mode and POR the printer into normal user mode, press EXIT DIAGNOSTICS.
  • Page 116 Print Quality Test Page 3-28 Service Manual...
  • Page 117 Print Quality Test Page Diagnostic Aids 3-29...
  • Page 118 5050-001 3-30 Service Manual...

  • Page 119: Repair Information

    5050-001 4. Repair Information Precautions for Disassembly and Cleaning Observe the following precautions whenever you service the printer: • Be sure to unplug the printer from the outlet before attempting to service the printer. • To reassemble the printer, reverse the order of disassembly unless otherwise specified.

  • Page 120: Precautions For Handling The Drum Cartridge

    5050-001 During Replacement: • Before you unplug connectors from the circuit boards, be sure the power cord has been unplugged from the power outlet. • When you remove a board from its conductive bag or case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the board.

  • Page 121: Parts Not To Be Touched

    5050-001 Parts not to be touched Any part where the mounting screws are painted red, such as the printhead, must not be removed, disassembled or adjusted. Adjustment Procedures The transfer belt tracking adjustment is the only mechanical adjustment in this printer. The other adjustments are in the form of printer setup settings entered into the printer from the diagnostic mode.
  • Page 122 5050-001 To make the adjustment: 1. Be sure the transfer belt unit is installed correctly and the 6 mounting screws are tight. 2. Insert an allen wrench into the hole in the offset collar. Use the wrench as a lever to rotate the collar clockwise or counter- clockwise and adjust belt tracking.

  • Page 123: Thermistor Rank Adjustment

    5050-001 • If the belt tracks too far to the right, rotate the collar clockwise. • If the belt tracks too far to the left, rotate the collar counter- clockwise. Thermistor Rank Adjustment Make this adjustment whenever you replace the transfer belt unit or when you replace the EEPROM on the printer controller board.

  • Page 124: Top Margin For Black And White Mode

    5050-001 • Transfer Belt Unit • LED Head • EEPROM Printer Controller • Printer Controller Board You must set the top margin for each cassette and the MPF. “CMY Top Margin Adjust Print Tests” on page 3-11. Top Margin for Black and White Mode Make this adjustment whenever you replace the following parts: •...

  • Page 125: Test Print 1

    5050-001 The X, Y, and Theta adjustment must be checked with the radar test page found in the X Adjustment menu, (Test Print) sub menu. This adjustment depends on the combination of 3 settings for color registration, X, Y, and Theta. Follow the procedure closely as the adjustment is critical.
  • Page 126 5050-001 12. When all the values are acceptable for all colors, exit diagnostics. Example of the Adjustment Here is a sample of the magenta radar image. Looking down the left side for both X and Y you can see the X value is close to correct. It may be a little to the right.
  • Page 127 5050-001 Summary Notes: X and Y values are taken from the left side. Theta is taken from the right. Increasing values for X drives the color radar right. Increasing values for Y and Theta drive the color radar image down the page. Do both the X and Y before attempting Theta.

  • Page 128: Removal Procedures

    5050-001 Removal Procedures LED Head Removal Open the top cover and remove the toner cartridge and PC drum. Be sure to set them away from bright light. 1. Remove the left and right head covers. 2. Remove the left and right pressure bases, (3 black screws). Be careful of the LED head because nothing is supporting it at this time.

  • Page 129: Transfer Belt Unit Removal

    5050-001 Transfer Belt Unit Removal Never turn the transfer belt unit upside down. 1. Hold the top of the printer and press the upper unit release button to open it. 2. Remove the 4 toner cartridges and PC drum sets. Place them in a safe place away from bright light.

  • Page 130: Paper Remaining Sensor Removal

    5050-001 Installation Notes: 1. After you replace the belt, do the transfer belt adjustments. Run tests in the service mode. Enter the thermistor rank value and adjust the print position (top margin K and C) in the service mode. Check the belt tracking. 2.
  • Page 131 5050-001 3. Remove the UD frame. 4. Remove the connector and remove the BUD sensor from the UD frame. 4-13 Repair Information...

  • Page 132: Engine Board (Pg14 Eng Bb) Removal

    5050-001 5. Disconnect the BUD motor connector and remove the 2 mounting screws. Remove the motor. Engine Board (PG14 ENG BB) Removal 1. Remove the belt unit. Do not turn it upside down. 2. Lift the engine board bracket. Be careful not to damage the harness.

  • Page 133: Cover Removals

    5050-001 Cover Removals 4-15 Repair Information...
  • Page 134 5050-001 1. Open the paper exit cover and remove the screw in the right, rear sub cover. Place a screwdriver between the right side cover and the sub cover then move the sub-cover toward the center of the printer and lift it out. 2.
  • Page 135 5050-001 3. Push the latch to lift the top cover, remove the 5 black mounting screws and remove the top cover. 4. Remove the second paper cassette connector cover on the bottom of the rear cover. 5. Remove the rear paper exit tray if it is installed. 6.
  • Page 136 5050-001 10. Open the paper exit cover and remove the paper exit unit by sliding it toward the rear. To remove the front cover: 1. Remove the paper cassette and open the MPF. 2. Remove the 4 silver mounting screws and unlatch the upper part of the front cover.
  • Page 137 5050-001 To remove the left side cover: 1. Remove the 4 silver mounting screws and remove the left side cover. Remove the 2 screws that mount the left side sub-cover. 4-19 Repair Information...
  • Page 138 5050-001 To remove the right side cover: 1. Remove the 4 silver screws that mount the right side cover. Remove the 2 screws that mount the right side sub-cover. 4-20 Service Manual...

  • Page 139: Head Controller Board (P614 Hdcont) Removal

    5050-001 Head Controller Board (P614 HDCONT) Removal 1. Remove the top cover. 2. Remove the harness connector from the HDCONT board. 3. Remove the 3 flat cables from the HDCONT board. 4. Remove the grounding wires from the shield plate. 5.

  • Page 140: Operator Panel Removal

    5050-001 8. Remove the head controller board from the mounting board, (6 screws.) Operator Panel Removal 1. Remove the front cover, (4 silver screws). 2. Remove the connector and ground wire. 3. Remove the 2 screws from the operator panel mounting bracket.

  • Page 141: Mpf Removal

    5050-001 MPF Removal 1. Remove the front cover. 2. Remove the right MPF plate, (2 screws). 3. Remove the left MPF plate, (2 screws). 4-23 Repair Information...

  • Page 142: Paper Feed Roller Removal

    5050-001 4. Remove the bearing stoppers from each side of the MPF(U). Release and turn the bearing position clips 90 degrees toward the front. Paper Feed Roller Removal 1. Remove the rear cover and the right side cover. 2. Move the plunger of the paper feed clutch solenoid out of the way to make the clutch move freely.

  • Page 143: Mpf Roller

    5050-001 MPF Roller 1. Remove the front cover. 2. Remove the MPF(U). 3. Remove the bearing stoppers from each side of the MPF(U). Release and turn the bearing position clips 90 degrees toward the front. 4. Remove the E-ring and MPF clutch. Assembly Note: Put conductive grease on the contact portion between the shaft of the resist roll and the resist roller ground plate.

  • Page 144: F Pad Removal

    5050-001 F Pad Removal 1. Remove the MPF roller. 2. Remove the pad by releasing 2 latches. Clean the paper feed roller surface with a cloth dampened with alcohol. Registration Sensor Removal 1. Remove the MPF roller. 2. Remove the connector and lift out the sensor. 4-26 Service Manual...

  • Page 145: Mpf Paper Empty Sensor Removal

    5050-001 MPF Paper Empty Sensor Removal 1. Remove the front cover. 2. Remove the connector and lift out the sensor from the MPF sensor bracket. Humidity Sensor Removal 1. Remove the rear cover and the right side cover. 2. Remove the connector and remove the humidity sensor, 1 black screw.

  • Page 146: Printer Controller (614 Prcont) Removal

    5050-001 Printer Controller (614 PRCONT) Removal 1. Remove the rear cover and the right side cover. 2. Remove the connector and the printer control board, (6 screws.) Installation Notes: • Be sure to take the EEPROM (U107) from the old board and install it on the new board.

  • Page 147: Hvu1(U) Removal

    5050-001 HVU1(U) Removal 1. Remove the printer controller board. 2. Remove the harness from the wire saddle. 3. Remove the connector. 4. Remove the 7 mounting screws. 5. Remove HVU1(U) from the HVU bracket, (9 screws). Drive 2 (U) and Face Up/Face Down (FUD) Solenoid Removal 1.

  • Page 148: Fuser Removal

    5050-001 4. Remove the FUD solenoid from the mounting bracket stay, (2 black screws). 5. Remove the Drive 2, (7 black screws). Fuser Removal Before you remove the fuser, mark its position with a pencil so you can install it to the same place. 4-30 Service Manual...
  • Page 149 5050-001 You can also note the position of the fuser on the embossed scale on the bottom of the fuser frame. Identification of high/low voltage fuser can be determined by either a red/low or a blue/high wire for the fuser connector. After you install the fuser, run a test print.
  • Page 150 5050-001 3. Remove the thermistor harness connector. 4. Remove the harness connector from the power supply board. 4-32 Service Manual...
  • Page 151 5050-001 5. Remove the 3 black fuser mounting screws. 6. Lift the fuser out of the printer. When you reinstall the fuser, be careful not to damage the fuser exit sensor actuator. 4-33 Repair Information...

  • Page 152: Fuser Thermostat, Fuse, And Thermistor Removals

    5050-001 Fuser Thermostat, Fuse, and Thermistor Removals 1. Remove the fuser cleaner. 2. Remove the 2 release levers and stopper screws. 3. Unlatch the center of the fuser guide, slide it to the right and remove the fuser guide. 4-34 Service Manual...
  • Page 153 5050-001 4. Remove the temperature fuse, (silver screw with washer). 4-35 Repair Information...
  • Page 154 5050-001 5. Remove 1 screw and the terminal. 6. Remove the thermistat switch from the terminal, (1 silver screw with washer). 7. Remove the thermistor, (1 silver screw with washer). 4-36 Service Manual...

  • Page 155: Fuser Press Roller Removal

    5050-001 Fuser Press Roller Removal 1. Remove the fuser cleaner and the fuser guide, 2. Remove the lock screw, wave washer and washer. 3. Slide the fuser cover toward the driving side and remove the fuser cover to the upper side. 4.
  • Page 156 5050-001 5. Open the guide retainer. 6. Remove the press roller. 4-38 Service Manual...

  • Page 157: Fuser Pawl Removal

    5050-001 Fuser Pawl Removal Be careful not to damage the edge of the pawl or the fuser roll. 1. Remove the fuser oiler roller, fuser guide and fuser cover. 2. Remove the press spring. 3. Remove the 2 stopper screws and the guide stay. 4-39 Repair Information...
  • Page 158 5050-001 4. Remove idler gear 18. 5. Pull out the pawl holder stay and remove it, 5 screws. Be careful not to damage the fuser roller surface. 4-40 Service Manual...
  • Page 159 5050-001 6. Remove the pawl from the holder stay. Be careful to not lose the spring. 4-41 Repair Information...

  • Page 160: Fuser Heater Removal

    5050-001 Fuser Heater Removal Be careful not to damage the heater glass. Do not touch the lamp with your fingers. Wipe with alcohol if it is necessary to clean. 1. Remove the fuser guide and the fuser cover. 2. Remove the harness from the terminal, 2 silver screws with washers.
  • Page 161 5050-001 4. Remove the left heater plate from the left side. 5. Hold the insulator and pull it out from the heat roller. 4-43 Repair Information...

  • Page 162: Fuser Heat Roller And Gear H, Gear 30 Removal

    5050-001 Fuser Heat Roller and Gear H, Gear 30 Removal 1. Remove the fuser heater. 2. Remove the guide stay. 3. Remove the pawl holder stay. 4. Remove the right heater plate. 5. Remove the fuser roller. 6. Remove gear H. 4-44 Service Manual...

  • Page 163: Heater Drive Board, 230 V Only

    5050-001 Heater Drive Board, 230 V Only 1. Remove the rear cover, front cover, and left side cover. 2. Remove the HK bracket, (2 screws). 3. Remove the connector. 4. Remove the HDRV board from the HK bracket, (2 screws). 4-45 Repair Information...

  • Page 164: Hvu 2 Removal

    5050-001 HVU 2 Removal 1. Remove the rear cover, the front cover, and the left side cover. 2. Remove the connector and HVT bracket. 3. Remove the HVU 2 from the HVT bracket, (6 screws). Power Supply Switch Removal 1. Remove the rear cover, the front cover, and the left side cover. 2.

  • Page 165: Power Supply Board (P614-Mps) Removal

    5050-001 Installation Note: When you connect the terminals be sure to connect them to the correct position. Also, after the terminals are connected, firmly insert the insulating cover. Power Supply Board (P614-MPS) Removal 1. Remove the rear cover, the front cover, and the left side cover. 2.

  • Page 166: Size Sensor Board (P611-Psz) Removal

    5050-001 Size Sensor Board (P611-PSZ) Removal 1. Remove the rear cover, the front cover, and the left side cover. 2. Remove the power supply board. 3. Remove the HDRV board (230 V only). 4. Remove the connector and the PSZ bracket, (2 screws). 5.
  • Page 167 5050-001 6. Remove the drum gear sensor, (2 black screws). 4-49 Repair Information...

  • Page 168: Drive 1 Removal

    5050-001 Drive 1 Removal 1. Remove the right sub-frame toner/drum gear sensor unit. 2. Remove the belt unit. 3. Remove the lock cover, (1 screw). 4. Remove the 6 outside mounting screws and 2 screws from inside the frame. Remove drive 1. Installation Note: When you connect the terminals be sure to connect them to the correct position.

  • Page 169: Drum Drive Gear Sensor (P614-Dgs) Removal

    5050-001 Drum Drive Gear Sensor (P614-DGS) Removal 1. Remove the gear cover. 2. Remove the rear cover, front cover, and right side cover. 3. Remove the printer controller board and high voltage unit 1. 4. Remove the drum drive gear sensor from drive 1, (1 screw). 4-51 Repair Information...

  • Page 170: Registration Roller Removal

    5050-001 Registration Roller Removal 1. Remove the rear cover, the front cover, and the right side cover. 2. Remove the right-front sub-cover. 3. Remove the connector from printer controller board. 4. Remove the lead line from the wire saddle. 5. Remove the registration roll, (4 black screws). Be careful of the lead line.

  • Page 171: Paper Feed Assembly Removal

    5050-001 Paper Feed Assembly Removal 1. Remove the rear cover, front cover, and right side cover. 2. Remove the MPF. 3. Remove the transfer belt assembly. 4. Remove the 2 screws. 5. Remove the front sub-cover, (2 screws). 6. Cut the cable tie off and remove the front frame, (4 screws). 4-53 Repair Information...
  • Page 172 5050-001 7. Remove the connector from the printer controller board and harness. 4-54 Service Manual...
  • Page 173 5050-001 8. Remove the MPF solenoid, (1 screw). 9. Remove the registration sensor and, the connector of the remaining paper sensor, and cut the cable tie. 4-55 Repair Information...
  • Page 174 5050-001 10. Press and slide the paper cassette support plate and remove the paper feed base, (4 screws). 11. Remove the turn guide, (4 screws). 4-56 Service Manual...

  • Page 175: Ohp Sensor Removal

    5050-001 12. Remove the paper feed clutch and the paper feed solenoid. 13. Remove the paper carrying roller. OHP Sensor Removal 1. Remove the rear cover, front cover, and right side cover. 2. Remove the MPF. 3. Remove connector CN132 and harness from the printer control board.
  • Page 176 5050-001 5. Remove the front sub-cover. 6. Cut the cable tie and remove the front frame. 7. Remove the transfer belt unit. 8. Remove the turn guide. 9. Remove connector CN131 and harness from the control board. 10. Remove the OHP sensor (LED), (1 screw). 4-58 Service Manual...

  • Page 177: Paper Exit Sensor Removal

    5050-001 Paper Exit Sensor Removal 1. Remove the rear cover. 2. Remove the connector. 3. Remove the paper exit photo interrupter. Be sure the actuator works correctly after you reassemble. Output Bin Full Sensor Removal 1. Remove the rear cover. 2.
  • Page 178 5050-001 5. Pull out the exit unit from the exit cover. Be careful of the output bin sensor harness. 6. Remove the paper full sensor from the exit cover. 4-60 Service Manual...

  • Page 179: Rip Controller Card Removal

    5050-001 RIP Controller Card Removal 1. Be sure the printer power is off and the power cord is unplugged. 2. If the rear output bin is attached to the back of the printer, lift it straight up and remove it from the printer. 3.

  • Page 180: Optional Paper Feeder Removal Procedures

    5050-001 Optional Paper Feeder Removal Procedures Outer Cover Removal 1. Remove the second cover. 2. Remove the screw and take off the latch of the upper side, and remove the rear cover, (1 silver screw). 3. Remove the right side cover, (3 silver screws). 4.

  • Page 181: Size Sensor Board (P611-Psz) Removal

    5050-001 Size Sensor Board (P611-PSZ) Removal 1. Remove the rear cover and the left side cover. 2. Remove the connector and the paper size board bracket, (2 screws). 3. Remove the size sensor board from the bracket (2 screws). 4-63 Repair Information...

  • Page 182: Drive Board (P614-2/3 Driv) Removal

    5050-001 Drive Board (P614-2/3 DRIV) Removal 1. Remove the rear cover and the right side cover. 2. Remove the connector from the drive board. 3. Remove the drive board and the bracket, (2 screws). 4. Remove the drive board from the bracket, (4 screws). Paper Feed Motor 2 (PM42) Removal 1.

  • Page 183: Paper Feed Roller Removal

    5050-001 Paper Feed Roller Removal 1. Remove the rear cover and the right side cover. 2. Move the plunger of the paper feed clutch solenoid out of the way to make the clutch move freely. Turn the paper feed roller and remove the screw.

  • Page 184: Paper Remaining Sensor Removal

    5050-001 Paper Remaining Sensor Removal 1. Remove the rear cover, the right side cover, and the left side cover. 2. Remove the front stay 2 plate, (5 screws). 3. Remove the connector and lift out the photo interrupter. 4-66 Service Manual...

  • Page 185: Paper Feed Clutch, Solenoid, And Transfer Roller Removal

    5050-001 Paper Feed Clutch, Solenoid, and Transfer Roller Removal 1. Remove the rear cover, the right side cover, and the left side cover. 2. Remove the front stay 2 plate, (5 screws). 3. Remove the connector and lead line of the solenoid. 4.
  • Page 186 5050-001 6. Remove the paper feed guide, (2 black screws). 7. Remove the paper carrying roller. 4-68 Service Manual...

  • Page 187: Connector Locations

    5050-001 5. Connector Locations Paper Handling Connector Locations...

  • Page 188: Cross Section Of Printer

    5050-001 Cross Section of Printer Fuser Roller Absorption Roller Press Roller Registration Upper Roller (Metal) Heater Registration Roller (Rubber) Fuser Oil Roller Registration Sensor Paper Exit Sensor Lever Registration Sensor Lever Belt Drive Roller MPF Roller Belt Thermistor Feeder Friction Stop Pad Transfer Belt MPF Assembly Transfer Sheet...
  • Page 189 5050-001 Connector Locations...

  • Page 190: Electronic Board Layout

    5050-001 Electronic Board Layout Main Fan Operator Panel Power Supply Fan HVU1 Power Supply Printer Controller Board Paper Size Detection Board Printhead Controller Board Paper Size Detection Board Drive Unit 1 (2nd Paper Feeder Option) Power Switch Drive Unit 2 HVU2 RIP Controller Board Service Manual...

  • Page 191: Electrical Components

    5050-001 Electrical Components Connector Locations...

  • Page 192: Sensors

    5050-001 Sensors Connector Locations...

  • Page 193: Power Supply Board (614-Mps-E)

    5050-001 Power Supply Board (614-MPS-E) Connector Locations...

  • Page 194: High Voltage Unit 1 Board (614-Hvu1)

    5050-001 High Voltage Unit 1 Board (614-HVU1) Connector Locations...

  • Page 195: High Voltage Unit 2 Board (P614-Hvu2)

    5050-001 High Voltage Unit 2 Board (P614-HVU2) Connector Locations...

  • Page 196: Optional Paper Feed Controller Board (P614-2/3 Driv)

    5050-001 Optional Paper Feed Controller Board (P614-2/3 DRIV) 5-10 Connector Locations...

  • Page 197: Printhead Controller Board (P614-Hd Cont)

    5050-001 Printhead Controller Board (P614-HD CONT) 5-11 Connector Locations...

  • Page 198: Printer Controller Board (P614-Prcont)

    5050-001 Printer Controller Board (P614-PRCONT) 5-12 Connector Locations...

  • Page 199: Size Sensor Board (P611-Psz)

    5050-001 Size Sensor Board (P611-PSZ) 5-13 Connector Locations...

  • Page 200: Rip Controller Card

    5050-001 RIP Controller Card 5-14 Service Manual...

  • Page 201: Preventive Maintenance

    5050-001 6. Preventive Maintenance Maintenance Kit After printing approximately 100,000 pages, the message appears on the printer display. This 80 Scheduled Maintenance message indicates that it’s time to replace the following parts: Fuser Unit Belt Unit Paper Feed Rollers (2) Routine replacement of these parts ensures peak printer performance and helps prevent print quality problems and paper feed problems resulting from worn parts.

  • Page 202: Periodic Maintenance

    5050-001 Periodic Maintenance This table lists the parts to be periodically cleaned by the servicer. Paper Feed Unit: If there is dust or dirt, remove it and wipe the surface lightly with a dry • Paper Feed Roller cloth. If it is still dirty, clean with a •...

  • Page 203: Parts Catalog

    5050-001 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 204 5050-001 Assembly 1: Covers Parts Catalog...

  • Page 205: Assembly 1: Covers

    5050-001 Assembly 1: Covers 11G0101 Top Cover (115 V) 11G0650 Top Cover (230 V) 11G0716 Top Cover (100 V) - Japan 11G0102 Paper Stopper 11G0104 Side Cover Asm, L 11G0103 FC Cover 11G0129 Rubber Plate 11G0105 Sub Cover, L F 11G0546 Sub Cover, L R 11G0547...
  • Page 206 5050-001 Assembly 1 (cont.): Covers Parts Catalog...
  • Page 207 5050-001 Assembly 1 (cont.): Covers 1-29 11G0121 Mpf Holder 11G0524 Bracket Rh Mpf Tray 11G0525 Bracket Lh Mpf Tray 11G0631 Rear Paper Exit Tray Asm 11G0651 Screw, Mtg, Rear Paper Exit Tray 99A0001 Operator Panel Asm 99A0630 Bezel, Operator Panel 99A0541 Bezel, Operator Panel - Japan 11G0567...
  • Page 208 5050-001 Assembly 2: Paper Exit Parts Catalog...

  • Page 209: Assembly 2: Paper Exit

    5050-001 Assembly 2: Paper Exit 11G0149 Paper Exit Cover H 11G0151 Paper Exit Unit 11G0131 Paper Exit Cover 11G0150 Discharge Brush 11G0134 Roller Fitting Plate, Upper 11G0135 Paper Exit Roller 11G0132 Feed Guide 11G0133 Paper Delivery Flap 11G0137 Paper Exit Shaft, Upper 11G0140 Bushing 11G0138...
  • Page 210 5050-001 Assembly 3: Upper Unit Parts Catalog...

  • Page 211: Assembly 3: Upper Unit

    5050-001 Assembly 3: Upper Unit 11G0152 Head Frame 11G0159 LED Head Asm, LED Head EEPROM 11G0719 LED Head Asm, LED Head EEPROM Level 2 11G0160 Head Spring L 11G0161 Head Cover L 11G0162 Pressure Base, L 11G0502 Head Spring R 11G0163 Head Cover R 11G0164...
  • Page 212 5050-001 Assembly 3 (cont.): 7-10 Parts Catalog...
  • Page 213 5050-001 Assembly 3 (cont.): Upper Unit 11G0153 Hinge Stay 2 11G0154 Damper Right 11G0155 Damper Left 11G0555 LED Printhead Controller Board (P614-Hdcont) 11G0167 Insulator Shield, sheet 11G0168 Sealed Plate 11G0665 Head Cable (M) 230 V 11G0720 Head Cable (M) 100 V - Japan 11G0504 Head/cable (M) 115 V 11G0652...
  • Page 214 5050-001 Assembly 3 (cont.): 7-12 Parts Catalog...
  • Page 215 5050-001 Assembly 3 (cont.): 11G0501 Bracket Ground Plate 11G0157 Ground Plate, Head Frame 11G0672 YLFG Harness 11G0673 KLFG Harness 11G0674 FRFG Harness 11G0678 Top Cover Spring 11G0679 Cover 11G0680 FFC Spring A 11G0681 FFC Spring B 11G0339 Ground Plate 11G0682 Side Ground Plate 11G0683 Ground Plate...

  • Page 216: Assembly 4: Base 1

    5050-001 Assembly 4: Base 1 7-14 Parts Catalog...
  • Page 217 5050-001 Assembly 4: Base 1 11G0176 Top Frame 11G0177 Side Frame; L 11G0178 Power Supply Bracket A 11G0179 Power Supply Stay 11G0180 Power Supply Bracket B 11G0181 Front Stay USA 11G0691 Front Stay Non-USA 11G0182 Front Frame, B 11G0183 Front Frame 11G0184 Bottom Frame 11G0185...
  • Page 218 5050-001 Assembly 4 (cont.): 7-16 Parts Catalog...
  • Page 219 5050-001 Assembly 4 (cont.): Part Units Description Number 4-32 11G0692 PCB Guide 11G0693 Ground Spring, LV 11G0694 Ground Spring, RV 11G0695 Cover Spring 11G0696 Spring 11G0697 Cover Bracket Spring R 7-17 Parts Catalog...
  • Page 220 5050-001 Assembly 5: Base 2 7-18 Parts Catalog...
  • Page 221 5050-001 Assembly 5: Base 2 11G0202 Transfer Belt Unit 11G0203 Belt toner Waste Bottle 11G0204 Transfer Cover 11G0205 Gear Cover 11G0208 Sub Frame Asm, Lm 11G0554 Sub Frame Asm, Lc 11G0557 Sub Frame Asm, Ly 11G0560 Sub Frame Asm, Lk 11G0209 Paper Carrying Guide 11G0210...
  • Page 222 5050-001 Assembly 5 (cont.): Base 2 7-20 Parts Catalog...
  • Page 223 5050-001 Assembly 5 (cont.): Base 2 5-31 11G0219 Photo Interrupter, Belt Up/Down (BUD) Sensor 11G0267 Changing Shaft 11G0232 Bushing 11G0233 Hook Shaft 11G0234 Hook 11G0235 Interlock Lever, Rear 11G0236 Interlock Lever Bracket 11G0239 Link Base 11G0238 Open Spring 11G0237 Open Button 11G0242 Link 11G0241...
  • Page 224 5050-001 Assembly 5 (cont.): 7-22 Parts Catalog...
  • Page 225 5050-001 Assembly 5 (cont.): Base 2 11G0543 Sub Frame Asm, Rm 11G0544 Sub Frame Asm, Rc 11G0545 Sub Frame Asm, Ry 11G0206 Sub Frame Asm, Rk 11G0207 Toner Sensor (A) Asm (611-Tn) 11G0548 Drum Sensor, Color, (A) Asm (614-dss) 11G0550 Drum Sensor, Black (A) Asm (614-dss) 11G0505 Paper Face Up/Face Down Sensor Cable...
  • Page 226 5050-001 Assembly 5 (cont.): 7-24 Parts Catalog...
  • Page 227 5050-001 Assembly 5 (cont.): 5-85 11G0626 Setting Label, M R 11G0627 Setting Label, Cr 11G0628 Setting Label, Yr 11G0629 Setting Label, Bkr 11G0699 Exit Sensor Cover 11G0700 Face Up/Down Sensor Cover 11G0725 Exit Sensor Grid 11G0540 Screw Parts Packet #5 7-25 Parts Catalog...
  • Page 228 5050-001 Assembly 6: Feeder 7-26 Parts Catalog...

  • Page 229: Assembly 6: Feeder

    5050-001 Assembly 6: Feeder 11G0304 Paper Feed Unit 11G0268 Registration Roller Asm 11G0269 Registration Clutch 11G0270 Auxiliary Roller 11G0271 Paper Feed Roll Asm 11G0272 Paper Feed Shaft 11G0273 Guide Stay Sheet 11G0274 Ground Plate Guide 11G0275 Sensor Stay 11G0219 Photo Interrupter, Registration Sensor 11G0276 Registration Sensor Lever 11G0277...
  • Page 230 5050-001 Assembly 6 (cont.): Feeder 7-28 Parts Catalog...
  • Page 231 5050-001 Assembly 6 (cont.): Feeder 6-34 11G0435 Solenoid Spring 11G0293 Clutch Lever 11G0294 Solenoid Bracket 11G0295 Cassette Support Plate 11G0296 Paper Feed Ground Plate 11G0297 Carrying Gear 11G0298 Idler Gear 11G0299 Idler Gear 35 11G0300 W Gear 21 x 39 11G0301 Idler Gear 38 11G0701...
  • Page 232 5050-001 Assembly 7: Electrical 7-30 Parts Catalog...

  • Page 233: Assembly 7: Electrical

    5050-001 Assembly 7: Electrical 11G0305 MPS, Power Supply (P611-MPS) (115 Volt) 11G0541 MPS, Power Supply (P611-MPS-E) (230 Volt) 11G0306 Interlock Rod Lever Bracket 11G0307 Interlock Rod Lever 11G0308 Insulation Sheet, MPS 11G0309 Sealed Plate, MPS 11G0319 Power Switch Cable 11G0322 Fan, Power Supply 11G0323 Fan, Main...
  • Page 234 5050-001 Assembly 7 (cont.): 7-32 Parts Catalog...
  • Page 235 5050-001 Assembly 7 (cont.): Electrical 11G0310 Paper Size Board A (P611-PSZ) 11G0311 Paper Size Bracket 11G0312 Size Sensor Plate 11G0313 High Voltage Unit 2 (P614-HVU2) 11G0314 Hvt Bracket 11G0315 Plate Holder 11G0316 Plate, Feeder 11G0317 Hv Cable 11G0318 Power Switch 11G0319 Power Switch Cable 11G0320...
  • Page 236 5050-001 Assembly 7 (cont.): 7-34 Parts Catalog...
  • Page 237 5050-001 Assembly 7 (cont.): 7-NS 11G0562 Screw Parts Packet #7 11G0726 Insulator Sheet (HVT) 11D0328 Power Cord, U.S, Canada, APG (LV), LAD (LV) 11D0333 Power Cord, Denmark 11D0334 Power Cord, Europe, England 11D0334 Power Cord, France 11D0334 Power Cord, Germany 11D0335 Power Cord, Italy 11D0334...
  • Page 238 5050-001 Assembly 8: I/F Controller 7-36 Parts Catalog...

  • Page 239: Assembly 8: I/F Controller

    5050-001 Assembly 8: I/F Controller 11G0604 RIP Controller Card 11G0605 Riser Card 11G0606 11G0607 16MB Solid State Drive 11G0714 20MB Solid State Drive - Japan 11G0608 16MB SIMM EDO, 50ns 11G0609 32MB SIMM EDO, 50ns 11G0611 Bracket, Riser Card 11G0612 Tray, Controller Card 11G0613 Screw, Fan...
  • Page 240 5050-001 Assembly 9: Fuser 7-38 Parts Catalog...

  • Page 241: Assembly 9: Fuser

    5050-001 Assembly 9: Fuser 11G0603 Fuser Oil Roll 11G0542 Fuser (230 Volt) 11G0375 Fuser (115 Volt) 11G0722 Fuser (100 Volt) - Japan 11G0342 Fuser Cover 11G0619 Caution Label, Fuser Cover 11G0343 Lock 11G0344 Lock Screw 11G0345 Fuser Guide 11G0346 Release Lever 11G0347 Screw 11G0549...
  • Page 242 5050-001 Assembly 9 (cont.): Fuser 7-40 Parts Catalog...
  • Page 243 5050-001 Assembly 9 (cont.): Fuser 9-28 11G0367 Fuser Frame 11G0368 Heater Plate, L 11G0369 Bushing Holder 11G0564 Bearing Holder 11G0370 Compression Spring 11G0371 Gear Holder 11G0372 Heater Plate, R 11G0373 Idler Gear, 18 11G0374 Stay, Bracket 11G0711 Paw Bracket 11G0662 Pawl Spring 11G0663 Separation Pawl...
  • Page 244 5050-001 Assembly 10: Cassette 7-42 Parts Catalog...

  • Page 245: Assembly 10: Cassette

    5050-001 Assembly 10: Cassette 10-1 11G0376 Lower Base 11G0377 Lower Plate 11G0378 Side Location, R 11G0379 Click, R 11G0380 Lower Plate Push Lever, R 11G0381 Lever Lock 11G0382 Lock Spring 11G0383 Push Up Spring 11G0387 Rear Location Plate 11G0388 Side Lock 11G0389 Side Location, L 11G0390...
  • Page 246 5050-001 Assembly 11: Optional Feeder Base 7-44 Parts Catalog...

  • Page 247: Assembly 11: Optional Feeder Base

    5050-001 Assembly 11: Optional Feeder Base 11-2 11G0397 Rear Cover, 2 11G0107 Second. Connector Cover 11G0129 Rubber Plate 11G0411 Mini Bushing, B 11G0412 Spring Hook 11G0193 Lock Cover, A 11G0192 Lock Cover, B 11G0196 Bottom Frame Cover 11G0191 Cassette Ground Plate 11G0195 Cassette Rail 11G0310...
  • Page 248 5050-001 Assembly 11 (cont.): 7-46 Parts Catalog...
  • Page 249 5050-001 Assembly 11 (cont.): 11-37 11G0421 Drive Frame In, 2 11G0422 Gear, Idler 62 11G0423 Gear, S37xs24 11G0424 Gear, H97xs34 11G0414 Paper Feed Motor (Pm42) Optional Feeder 11G0415 Motor Harness 11G0416 Pcb Bracket 11G0417 Paper Feeder Driver Board (P614-2/3 DRIV) 11G0418 Side Cover, R 2 11G0419...
  • Page 250 5050-001 Assembly 11 (cont.): Optional Feeder Base 7-48 Parts Catalog...
  • Page 251 5050-001 Assembly 11 (cont.): Optional Feeder Base 11-1 11G0396 Top Frame, 2 11G0398 Side Cover, L 2 11G0129 Rubber Plate 11G0399 Ground Plate, Second 11G0400 Lock, 2 11G0401 Lock Shaft, 2 11G0402 Lock Link 11G0403 Lock Lever 11G0404 Lock Spring, 2 11G0245 Paper Detect Lever 11G0243...
  • Page 252 5050-001 Assembly 12: Optional Feeder Paper Feed 7-50 Parts Catalog...

  • Page 253: Assembly 12: Optional Feeder Paper Feed

    5050-001 Assembly 12: Optional Feeder Paper Feed 12-1 11G0426 Paper Feed Base, 2 11G0270 Auxiliary Roller 11G0271 Paper Feed Roller 11G0272 Paper Feed Shaft 11G0290 Bushing, B 11G0140 Bushing, 8a 11G0291 Paper Feed Clutch 11G0430 Idle Gear 27 11G0303 Metal Bushing 8 11G0297 Carrying Gear 11G0431...

  • Page 254: Assembly 13: Optional Features

    5050-001 Assembly 13: Optional Features 11G0601 Maintenance Kit Low Voltage 11G0602 Maintenance Kit High Voltage 11G0727 Maintenance Kit - Japan 11G0632 Machine Return Packaging Material 11G0733 Hard Disk 11G0610 Cable, Hard Disk 99A0422 Ethernet 10BaseT and 10Base2 99A0421 Ethernet 10/100BaseT 99A0420 Token-Ring, (Connects via DB9 or RJ45) 99A0560...
  • Page 255 5050-001 Index 1-10 abbreviations electrical charge unit adjustment procedures electronic board layout adjustments and procedures following electro-photographic process 4-14 parts replacement engine board removal 2-13 3-27 attendance messages exiting diagnostic mode 1-11 exposure assembly belt unit drive frame, BUD motor, BUD 4-12 4-26 sensor removal...
  • Page 256 5050-001 4-24, 4-65 paper feed roller removal 4-10 1-14 LED head removal paper feed, transfer, and fusing LEDs paper FUD delivery sensor removal 2-40 4-61 cleaning 3-14 light quantity paper handling 2-30 lubricants and cleaners paper jam service check paper low/empty tray 1, 2, 3 service 2-35 check 1-25...
  • Page 257 5050-001 1-17, 2-41 registration viewing and resetting the drum 4-52 3-24 registration roller removal counters 4-26 3-25 registration sensor removal viewing the error log 4-10 removal procedures viewing the permanent page count 3-23 remove paper sensor service check 2-36 5-14 RIP controller card layout 4-61 RIP controller card removal...
  • Page 258 5050-001 Service Manual...
  • Page 259 P/N 12G0169 (U.S.) P/N 11F0867 (Japan) October, 1998 You may use this form to communicate your comments about this publication, with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you.
  • Page 260 BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 2659 LEXINGTON, KY POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 | | | | | |...

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