1200 COLOR Service Manual.PDF

5050-001Optra Color 1200TM

Lexmark and Lexmark with diamonddesign are trademarks of LexmarkInternational, Inc., registered in theUnited States and/or other countries.

Table of Contents

Index

Safety and Notices

Trademarks

Start Diagnostics

Manuals Menu

Service.bk Page i Tuesday, November 30, 1999 1:51 PM

First Edition (October, 1998)The following paragraph does not apply to any country where such provisions areinconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THISPUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS ORIMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do notallow disclaimer of express or implied warranties in certain transactions, therefore, thisstatement may not apply to you.This publication could include technical inaccuracies or typographical errors. Changes areperiodically made to the information herein; these changes will be incorporated in latereditions. Improvements or changes in the products or the programs described may bemade at any time.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 ordistribute any of the information you supply in any way it believes appropriate withoutincurring any obligation to you. You can purchase additional copies of publications relatedto this product by calling 1-800-553-9727. In other countries, contact your point ofpurchase.Lexmark,FontVision, MarkVision, and Optra are trademarks of Lexmark International,Inc., registered in the United States and/or other countries.Other trademarks are the property of their respective owners. Copyright Lexmark International, Inc. 1998.All rights reserved.UNITED STATES GOVERNMENT RESTRICTED RIGHTSThis software and documentation are provided with RESTRICTED RIGHTS. Use,duplication or disclosure by the Government is subject to restrictions as set forth insubparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause atDFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,Lexington, KY 40550.

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Contents

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ixSafety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ixGeneral Information

Maintenance ApproTools . . . . . . . . . .Serial Number . . .Abbreviations . . .Standard FeaturesOptions . . . . . . . . .Printer Supplies . .Cross Section of Pr

Operational Theory . .ElectrophotographicPhotoconductor DruElectrical Charge UExposure AssemblyDeveloper AssembTransfer AssemblyCleaning AssemblyPaper Feed, TransfPrint Modes . . . . .

Clearing Paper JamsPrinting From the M

Diagnostic InformatioPart Numbers . . . .Adjustments and P

Start . . . . . . . . . . . . .Initial Check . . . . .

Printer Messages . . .Service Error MessStatus Messages .Attendance MessagSymptom Table . .

Service Checks . . . .Fuser Service ChecColor Print Unit MisDrive 1 DC Motor SDrive 2 Stepper Mo

Service.bk Page iii Tuesday, November 30, 1999 1:51 PMiii

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1ach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6inter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10nit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13er, and Fusing . . . . . . . . . . . . . . . . . . . . . . . 1-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27ultipurpose Feeder . . . . . . . . . . . . . . . . . . . 1-28n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1rocedures Following Parts Replacement . . . . 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3age Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28sing Service Check . . . . . . . . . . . . . . . . . . . 2-29ervice Check . . . . . . . . . . . . . . . . . . . . . . . . 2-29tor Service Check . . . . . . . . . . . . . . . . . . . . 2-30

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Transport Belt/BUD Service Check . . . . . . . . . . . . . . . . . . . . . . .2-30Optional Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . .2-31Paper Jam Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31Paper Carrying Service Check . . . . . . . . . . . . . . . . . . . . . . . . . .2-33Paper Exit FU/FD Service Check . . . . . . . . . . . . . . . . . . . . . . . .2-35Paper Low/Empty Tray 1, 2, 3 Service Check. . . . . . . . . . . . . . .2-36Paper Tray MissingRemove Paper SenPower Supply ServMarks on Paper Se

Image Quality TroublePrint Quality ProbleSensor Service Che

Diagnostic Aids . . . .Power-On Self TesUsing the OperatorOperator Panel ButPrinting the Menu SOperator Menu DisMenu Overview . . .Diagnostic Mode . .Diagnostic Menu GSetting Printer top MColor Calibration of

Print Tests . . . . . . . .Input/Output SourcePrint Quality PagesLCD Hardware TesButton Test . . . . . .DRAM Memory TesStd Parallel Wrap TSerial Wrap Tests .Quick Disk Test . .Disk Test/Clean . .Setting the Page CoViewing the PermanViewing and ResettCalibrating the TranViewing the Error LClearing the Error LUS / Non-US . . . . .Exiting Diagnostics

Service.bk Page iv Tuesday, November 30, 1999 1:51 PM/Size Service Check . . . . . . . . . . . . . . . . . . .2-36sor Service Check . . . . . . . . . . . . . . . . . . . .2-37ice Check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37rvice Check . . . . . . . . . . . . . . . . . . . . . . . . . .2-38shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39ck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1t Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2tons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3ettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4abled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6roup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6argin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15Print Tests . . . . . . . . . . . . . . . . . . . . . . . . .3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17est and Parallel X Wrap Test . . . . . . . . . . .3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21unt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23ent Page Count . . . . . . . . . . . . . . . . . . . . .3-23ing the Drum Counters . . . . . . . . . . . . . . . .3-24sparency Sensor . . . . . . . . . . . . . . . . . . . . .3-24og . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25og . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27

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Test Print 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28Test Print 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Precautions for Disassembly and Cleaning . . . . . . . . . . . . . . . . 4-1Handling the Printed Circuit Boards with MOS ICs . . . . . . . . . . . 4-1Precautions for HanParts not to be touc

Adjustment ProcedureTransfer Belt TrackThermistor Rank AdLED Head Light QuTop Margin for ColoTop Margin for BlacOverhead ProjectioPrinthead Adjustme

Removal ProceduresLED Head RemovaTransfer Belt Unit RPaper Remaining SBelt Unit Drive FramEngine Board (PG1Cover Removals. .Head Controller BoOperator Panel RemMPF Removal . . .Paper Feed RollerMPF Roller . . . . . .F Pad Removal . .Registration SensoMPF Paper EmptyHumidity Sensor RePrinter Controller (6HVU1(U) RemovalDrive 2 (U) and FacFuser Removal . .Fuser Thermostat,Fuser Press RollerFuser Pawl RemovFuser Heater RemoFuser Heat Roller aHeater Drive BoardHVU 2 Removal .

Service.bk Page v Tuesday, November 30, 1999 1:51 PMv

dling the Drum Cartridge . . . . . . . . . . . . . . . 4-2hed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3ing Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-3justment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5antity Adjustment . . . . . . . . . . . . . . . . . . . . . 4-5r Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5k and White Mode . . . . . . . . . . . . . . . . . . . . 4-6n Sheet Detection Sensor Adjustment . . . . . 4-6nts (X, Y, and Theta) . . . . . . . . . . . . . . . . . . 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10emoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11ensor Removal . . . . . . . . . . . . . . . . . . . . . . 4-12e, BUD Motor, BUD Sensor Removal . . . . 4-124 ENG BB) Removal . . . . . . . . . . . . . . . . . . 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15ard (P614 HDCONT) Removal . . . . . . . . . . 4-21oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26r Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26Sensor Removal . . . . . . . . . . . . . . . . . . . . . 4-27moval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2714 PRCONT) Removal . . . . . . . . . . . . . . . 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29e Up/Face Down (FUD) Solenoid Removal 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30Fuse, and Thermistor Removals . . . . . . . . . 4-34Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39val . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42nd Gear H, Gear 30 Removal . . . . . . . . . . 4-44, 230 V Only . . . . . . . . . . . . . . . . . . . . . . . . 4-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

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Power Supply Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-46Power Supply Board (P614-MPS) Removal . . . . . . . . . . . . . . . .4-47Size Sensor Board (P611-PSZ) Removal . . . . . . . . . . . . . . . . .4-48Toner Remaining Sensor, Drum Gear Sensor Removal . . . . . . .4-48Drive 1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50Drum Drive Gear Sensor (P614-DGS) Removal . . . . . . . . . . . .4-51Registration RollerOHP Sensor RemoPaper Exit Sensor ROutput Bin Full SenRIP Controller CardPaper Face Up/Fac

Optional Paper FeederOuter Cover RemovSize Sensor BoardDrive Board (P614-Paper Feed Motor 2Paper Feed Roller RPaper Remaining SPaper Feed Clutch,

Connector LocationsPaper Handling . . .Cross Section of PrElectronic Board LaElectrical ComponeSensors . . . . . . . . .Power Supply BoarHigh Voltage Unit 1High Voltage Unit 2Optional Paper FeePrinthead ControllePrinter Controller BSize Sensor BoardRIP Controller Card

Preventive MaintenanMaintenance Kit . .Periodic MaintenanLubricants and Clea

Parts Catalog . . . . . .How to Use This PartsAssembly 1: Covers . .

Service.bk Page vi Tuesday, November 30, 1999 1:51 PMRemoval . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52val . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57emoval . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59sor Removal . . . . . . . . . . . . . . . . . . . . . . . .4-59Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-61e Down (FUD) Delivery Sensor Removal . .4-61Removal Procedures . . . . . . . . . . . . . . . . .4-62al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62(P611-PSZ) Removal . . . . . . . . . . . . . . . . .4-632/3 DRIV) Removal . . . . . . . . . . . . . . . . . . .4-64(PM42) Removal . . . . . . . . . . . . . . . . . . . .4-64emoval . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-65ensor Removal . . . . . . . . . . . . . . . . . . . . . .4-66Solenoid, and Transfer Roller Removal . . .4-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1inter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2yout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4nts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6d (614-MPS-E) . . . . . . . . . . . . . . . . . . . . . . . .5-7Board (614-HVU1). . . . . . . . . . . . . . . . . . . . .5-8Board (P614-HVU2) . . . . . . . . . . . . . . . . . . .5-9d Controller Board (P614-2/3 DRIV) . . . . . .5-10r Board (P614-HD CONT) . . . . . . . . . . . . . .5-11oard (P614-PRCONT) . . . . . . . . . . . . . . . . .5-12(P611-PSZ) . . . . . . . . . . . . . . . . . . . . . . . . .5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2ners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

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Assembly 2: Paper Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6Assembly 3: Upper Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8Assembly 4: Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14Assembly 5: Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18Assembly 6: Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26Assembly 7: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30Assembly 8: I/F ControAssembly 9: Fuser. . .Assembly 10: CassetteAssembly 11: OptionalAssembly 12: OptionalAssembly 13: Optional

Service.bk Page vii Tuesday, November 30, 1999 1:51 PMvii

ller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42Feeder Base. . . . . . . . . . . . . . . . . . . . . . . . 7-44Feeder Paper Feed . . . . . . . . . . . . . . . . . . 7-50Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

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Safety Information

Safety Notice This producglobal safetycomponentsalways be obother replace

The maintenprepared forintended to b

There may bpersonal injuproduct. Prothis and take

Ce produit anormes striccomposantsscurit de cLexmark ned'autres pic

Les consigns'adressentqualifi.

Le dmontacertains risqdevra prend

Service.bk Page ix Tuesday, November 30, 1999 1:51 PMSafety Information ix

t is designed, tested and approved to meet strictstandards with the use of specific Lexmark. The safety features of some parts may notvious. Lexmark is not responsible for the use ofment parts.

ance information for this product has beenuse by a professional service person and is note used by others.

e an increased risk of electric shock andry during disassembly and servicing of thisfessional service personnel should understandnecessary precautions.

t conu, test et approuv pour respecter lestes de scurit globale lors de l'utilisation deLexmark spcifiques. Les caractristiques deertains lments ne sont pas toujours videntes.peut tre tenu responsable de l'utilisationes de rechange.

es d'entretien et de rparation de ce produituniquement un personnel de maintenance

ge et l'entretien de ce produit pouvant prsenterues lectriques, le personnel d'entretien qualifire toutes les prcautions ncessaires.

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Il prodotto stato progettato, testato e approvato inconformit a severi standard di sicurezza e per lutilizzo concomponenti Lexmark specifici. Le caratteristiche di sicurezzadi alcune parti non sempre sono di immediata comprensione.Lexmark nodi altri produ

Le informazprodotto sonautorizzato.

Durante lo sil rischio di selevato. Il peadottare le p

Dieses Prodentworfen ugltigen Sichsicherheitsresind nicht imwerden, diekeinerlei Verbernomme

Die WartungausschlielicWartungsfac

Whrend deGerts besteSchlags undFachpersonatreffen.

Service.bk Page x Tuesday, November 30, 1999 1:51 PMn responsabile per lutilizzo di parti di ricambiottori.

ioni riguardanti la manutenzione di questoo indirizzate soltanto al personale di assistenza

montaggio e la manutenzione di questo prodotto,ubire scosse elettriche e danni alla persona pirsonale di assistenza autorizzato, deve, quindi,recauzioni necessarie.

ukt und die zugehrigen Komponenten wurdennd getestet, um beim Einsatz die weltweiterheitsanforderungen zu erfllen. Dielevanten Funktionen der Bauteile und Optionenmer offensichtlich. Sofern Teile eingesetztnicht von Lexmark sind, wird von Lexmarkantwortung oder Haftung fr dieses Produktn.

sinformationen fr dieses Produkt sindh fr die Verwendung durch einenhmann bestimmt.

s Auseinandernehmens und der Wartung desht ein zustzliches Risiko eines elektrischenkrperlicher Verletzung. Das zustndigel sollte entsprechende Vorsichtsmanahmen

5050-001

Este producto se ha diseado, verificado y aprobado paracumplir los ms estrictos estndares de seguridad globalusando los componentes especficos de Lexmark. Puedeque las caractersticas de seguridad de algunas piezas nosean siemprdel uso de o

La informacest dirigidamantenimien

Existe mayopersonales dmquina. Elpeligro y tom

Este produtosatisfazer oscomponentesegurana dsempre bvide outros co

As informadestinam-seutilizadas po

Risco de chdesmontagedestes servicuidados ne

Service.bk Page xi Tuesday, November 30, 1999 1:51 PMSafety Information xi

e evidentes. Lexmark no se hace responsabletras piezas de recambio.

in sobre el mantenimiento de este productoexclusivamente al personal cualificado deto.

r riesgo de descarga elctrica y de daosurante el desmontaje y la reparacin de lapersonal cualificado debe ser consciente de estear las precauciones necesarias.

foi concebido, testado e aprovado parapadres globais de segurana na utilizao des especficos da Lexmark. As funes dee alguns dos componentes podem no seras. A Lexmark no responsvel pela utilizaomponentes de substituio.

es de segurana relativas a este produtoa profissionais destes servios e no devem serr outras pessoas.

oques elctricos e ferimentos graves durante am e manuteno deste produto. Os profissionaisos devem estar avisados deste facto e tomar oscessrios.

xii Service Manual

5050-001

Aquest producte est dissenyat, comprovat i aprovat per tald'acomplir les estrictes normes de seguretat globals amb lautililitzaci de components especfics de Lexmark. Lescaracterstiques de seguretat d'algunes peces pot ser que nosempre sigud'altres pece

La informacorientada exa ning que

El risc de xodurant el proproducte. Elprendre les m

Service.bk Page xii Tuesday, November 30, 1999 1:51 PMin bvies. Lexmark no es responsabilitza de l'uss de recanvi.

i pel manteniment daquest producte estclusivament a professionals i no est destinadano ho sigui.

c elctric i de danys personals pot augmentarcs de desmuntatge i de servei daquestpersonal professional ha destar-ne assabentat iesures convenients.

5050-001

Service.bk Page xiii Tuesday, November 30, 1999 1:51 PMSafety Information xiii

xiv Service Manual

5050-001

Service.bk Page xiv Tuesday, November 30, 1999 1:51 PM

5050-001

1. General Information

Maintenance Approach

The diagnostic information in this manual leads you to the correctfield replaceable unsymptom index, andrepair the failure. YoInformation chapter

After you completerepair.

Tools

The removal and adrequire the following

Magnetic tip Ph Flat-blade scre Analog volt ohm

used) Needle nose p Tweezers, C-rin Magnifier (10 ti 6-angle wrench

When you make voanother ground is s

Service.bk Page 1 Tuesday, November 30, 1999 1:51 PMGeneral Information 1-1

it (FRU) or part. Use the error code charts,service checks to determine the symptom andu may find that the removals in the Repairwill help you identify parts.

the repair, perform tests as needed to verify the

justment procedures described in this manualtools and equipment:

illips screwdrivers, large and smallwdriversmeter (a digital volt ohmmeter may also be

liersg pliersmes or equivalent)(1.5 mm).

ltage readings, always use frame ground unlesspecified.

1-2 Service Manual

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 canprint from the Tests Menu.

Service.bk Page 2 Tuesday, November 30, 1999 1:51 PM

5050-001

Abbreviations

ASIC Application-Specific Integrated CircuitCSU Customer SetupDRAM Dynamic Random Access MemoryEEPROM Electrically Erasable Programmable Read-

OnlyEP ElectESD ElectFRU FieldHVPS HighLAN LocaLASER Light

of RaLCD LiquiLED LightLVPS LowNVRAM NonvOEM OrigiPICS ProblPIXEL PictuPOR PowePOST PowePQET PrintRIP RasteROS ReadSRAM StaticUPR UsedVAC VoltsVDC Volts


Memoryrophotographic Processrostatic DischargeReplaceable UnitVoltage Power Supplyl Area NetworkAmplification by Stimulated Emissiondiationd Crystal Display-Emitting DiodeVoltage Power Supplyolatile Random Access Memorynal Equipment Manufacturerem Isolation Chartsre Elementr-On Resetr-On Self TestQuality Enhancement Technologyr Image Processor-Only StorageRandom Access MemoryParts Replacementalternating currentdirect current

1-4 Service Manual

5050-001

Standard Features

Print method Dry electrophotographic process using LED printheadsPrintaddressability

600

Maximum printspeed

12 12

Fonts 1. 75 Po36

PC30

2. PC Lin PO3. Fo4. W 77 Ca Po

Paper input 25 M

Paper output To Re

Paper sizessupported

A4, A

Printer memory 32MSom

Flash memory 4MB

Interface Parabidire

Internal solutionsports

2pa

1 2

Printer software MarkfromenvirWind

Service.bk Page 4 Tuesday, November 30, 1999 1:51 PMdpi

ppm (letter and A4 paper) (Color)ppm (Mono)resident scalable fonts:stScript Level 2 emulation: 39 Optra compatible plusadditionalL emulation: 45 LaserJet compatible plusadditionalL bitmap fonts:ePrinterSTNET BarcodentVisionTM font manager utility with 110 fontsorld class international font support:symbol sets, including support fornadian, French, Brazilian,rtuguese, Cyrillic, and Greek0-sheet trayultipurpose feeder

p output bin: 250 sheets (collated)ar output bin: 100 sheets (uncollated)5, JIS B4, JIS B5, A3, letter, legal, 11 x 17

B (two 16MB 50 ms EDO SIMMS)e printer models may ship with more memory.

(for permanent storage of fonts, logos, and forms)llel (standard Centronics protocol that complies withctional IEEE 1284B)ports for network adapters, tri-port adapters, orrallel port adaptersconnector for hard diskpairs of memory connectors

VisionTM utility that lets you manage your printeryour computer. Supported in the followingonments: Windows 95, Windows NT 4.0,ows 3.1x, OS/2 Warp, Macintosh, UNIX.

5050-001

Options

Optional drawer Support unit and 250-sheet tray; up to two drawers maybe installed underneath the printer

250-sheet tray Repl

Memory 32 64 M

Hard disk option 2.5-ispoo

Hard diskadapter ribboncable

For idisks

MarkNet Sinternal networkadapters

Adap

Et Et Tone

Tri-port adapter Prov

Seco

Hi Lo

Parallel portadapter

Prov

Infrared adapter For ufrom

Serial interfaceadapter

Conv

Parallel cables Highpara

Serial cable 50-fo


acement tray

MB option (two 16MB memory cards)MB option (two 32MB memory cards)aximum installed memory: 128MB

nch hard disk to store fonts, forms, job statistics, andled jobsnstalling compatible Lexmark or third-party hard

ters available to support the following topologies:

hernet 10BaseT and 10Base2hernet 10/100BaseTXken-Ring (connects the printer to a Token-Ringtwork via DB9 or RJ45)ides support for the following interfaces:

rial RS-232C/RS-422A (which can also benfigured to support a class 1 fax modem)gh speed Infrared local connectionscalTalk network connection

ides additional parallel port

se with the tri-port adapter; receives infrared beaman IrDA-compatible workstation

erts the printers parallel port to a serial port

speed bidirectional 10-foot and 20-foot 1284-Bllel cables; 9.8-foot 1284 A-C parallel cable

ot serial cable

1-6 Service Manual

5050-001

Printer Supplies

Cross Section of

Toner cartridges Black, magenta, cyan, or yellowcartridges

6,500 pages each(5% coverage)

Photoconductors Blaco

Cyphtog

Transparencies A4 a

1 Fuser Roller

2 Press Roller

3 Heater

4 Fuser Oil Rol

5 Paper Exit Se

6 Belt Drive Ro

7 Belt Thermist

8 Transfer Belt

9 Transfer Shee

10 Cleaning Bla11 Charging Rol12 Photoconduc

13 LED Printhea

14 Development

15 Developer Su

16 Developer Do

17 Developer Ag

Service.bk Page 6 Tuesday, November 30, 1999 1:51 PMPrinter

ck photoconductor (with fuserating roll)an, magenta, and yellowotoconductors (packagedether)

13,000 pages each

nd letter size

18 Absorption Roller

19 Registration Upper Roller (Metal)20 Registration Roller (Rubber)

ler 21 Registration Sensornsor Lever 22 Registration Sensor Leverller 23 MPF Roller

or 24 Feeder Friction Stop Pad

25 MPF Assembly

t 26 Paper Carrying Rollerde 27 Paper Noise-Cut Roller

ler 28 Pick-up Paper Feed Roller

tor Drum 29 Paper Remaining DetectionLever

d 30 Paper Remaining DetectionSensors

Roller 31 Transport Belt Blade

pply Roller 32 Transport Belt Waste Bottle

ctor Blade 33 Belt Unit Drive Motor

itator 34 Interface RIP Controller Card

General Information 1-7

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1-8 Service Manual

5050-001

Operational TheoryThis printer makes a color image by overlapping each color toner indot units and fusing them to the paper. The process is divided intotwo steps. The first step is the electrophotographic process whichforms the image onTransferring, Fusingthe paper and fuses

ElectrophotograpAs the photoconducimage is exposed tothe image is transfe

Service.bk Page 8 Tuesday, November 30, 1999 1:51 PMthe PC. The second step consists of Feeding,which feeds the paper, transfers the image tothe toner.

hic Processtor drum rotates it is electrically charged, thethe PC drum, the image is developed with toner,rred to the paper, and the PC drum is cleaned.


5050-001 Service.bkPage9

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1-10 Service Manual

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Photoconductor Drum

The photoconductor drum uses aluminum as the base material anda layer of organic photo conductor (OPC) on the surface. Acharacteristic of this layer is that only the part that the light shines onbecomes conductive.

Electrical ChargeThe charge roller ofsurface of the drumsensitive drum.

Service.bk Page 10 Tuesday, November 30, 1999 1:51 PMUnit

the electrical charge unit evenly charges the. The static latent image forms on the photo-

5050-001

Exposure Assembly

The exposure assembly uses an LED head to form an electrostaticimage by emitting light onto the charged drum. The length of timethe light is on is contained in non-volatile memory (EEPROM) in theprinter controller because the light emitting time of each LED isdifferent in every heemitting time must balso replace the EE

Developer Assem

The toner agitator sroller provides tonepressed to the deve

As the developmendeveloper roller andnegatively. As the todrum, it sticks to the


ad. When the LED head is replaced, the lighte reset. If you replace the LED head, be sure toPROM.

bly

tirs the toner in the cartridge.The toner supplyr to the development roller.The doctor blade islopment roller which is conductive rubber.

t roller rotates, toner feeds between thethe doctor blade. This friction charges the tonerner comes in contact with the photoconductorelectrostatic latent image.

1-12 Service Manual

5050-001

Transfer Assembl

Paper is held to thethe same speed asapplies a positive cphotoconductor drucharge from the tra

Service.bk Page 12 Tuesday, November 30, 1999 1:51 PMy

transfer belt electrostatically. The belt rotates atthe photoconductor drum. The absorption rollerharge to the paper. The toner formed on them transfers to the paper because of the positivensfer sheet under the transfer belt.

5050-001

Cleaning AssemblyThe cleaning blade scrapes off the remaining toner on thephotoconductor drum after the toner image has been transferred tothe paper.

A rotating coil in thescraped-off toner to


waste toner conveyance assembly conveys thethe waste toner bag.

1-14 Service Manual

5050-001

Paper Feed, Transfer, and FusingTwo drives perform the entire paper feed in this printer, drive 1 anddrive 2. There is a separate motor in the second paper feeder todrive the paper feed.

Drive 1

Drive 1 consists ofcarries paper fromalso drives the elecrunning after it recemotor then sends aWhen monochromeelectrophotographic

Do not disassembleadjustment has beemachine as the gea

Drive 2

Drive 2 consists ofdrives the fuser andfor this motor.

Service.bk Page 14 Tuesday, November 30, 1999 1:51 PMa brush-less dc motor and gear unit. Drive 1the paper feed unit to the registration unit andtrophotographic process. The motor startsives an ON signal from the printer controller. Thesynchronizing signal to the printer controller.mode is selected, clutch 2 interrupts theprocess for color printing.

the gears in drive 1 because the phasen preset. Do not turn the PC when it is out of thers will lose timing to work as a matched set.

a hybrid stepping motor and gear assembly. Itexit assembly. There is no synchronizing signal



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1-16 Service Manual

5050-001

Paper Cassette Feeder

The printer controller sends a signal to the paper feed solenoidwhich turns on and drives the paper feed roller connected to drive 1by a spring clutch. The paper in the cassette is picked one sheet at atime.

Multipurpose Feeder

After it receives a siturns on and drivesclutch. The paper inat a time.

Service.bk Page 16 Tuesday, November 30, 1999 1:51 PMgnal from the printer controller, the MPF solenoidthe MPF roller connected to drive 1 by a springthe multipurpose feeder is picked up one sheet

5050-001

Registration

Paper feed stops temporarily at the registration roller to make the topedge of the paper parallel to the photosensitive drum and to adjustfeed timing with the toner image on the photosensitive drum. Inparallel to the photosensitive drum, the rubber registration rollerpresses against theclutch controls the r

The registration senthrough, senses pathe electrophotogra


metal registration upper roller. The registrationegistration roller.

sor (photo-interrupter) detects paper as it feedsper jams and stops paper feed, and also startsphic process.

1-18 Service Manual

5050-001

Separation Assembly

The paper separates from the transfer belt at the drive roller sectionof the belt assembly. The electric charge on the paper is theneliminated by the discharge brush.


5050-001

Fuser Assembly

The press roller presses the paper with toner against the heatedfuser roller which fuses and fixes the toner to the paper. Theseparator pawl separates the paper from the fuser roller.

Exit Unit

The fused paper is

The exit sensor cheperforms the changup).As the paper leavesturns on the exit secontroller detects awithin the prescribethe prescribed time

Face down/face upthe flap lever (manu(automatic).


ejected from the printer.cks the state of the paper, while the flape-over of paper exit direction (face down, face

the fuser it pushes down the exit link whichnsor on the printer controller. The printerpaper jam if the exit sensor is not turned ond time or when it continues to be turned on past.

switching for paper exit is performed by switchingal) or by command from the interface controller

1-20 Service Manual

5050-001

When automatic switching is set (default), the face up/face down(FUD) solenoid is turned on by a signal from the printer controllerand 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.


5050-001

Transfer Belt

The positive-charged absorption roller charges the paper as it entersthe transfer belt. The belt rotates at the same speed as thephotoconductor drum.Toner is transferred to the paper in the order ofmagenta, cyan, yellow, and black. As the paper passes eachphotoconductor druaway from the drumit passes the drum.transfer belt waste t

Temperature changcompensate for theroller is monitored aaccordingly.

The transfer belt un100,000 pages. Whthermistor resistancmake the print adjuThere are two printthe color image regthe service mode.

The length of the traabout 320 mm. Thenot to scratch the bthe assembly. If tonprint, it will create dfind a stain on the b


m, the static from the transfer belt pulls toner. A little waste toner sticks to the transfer belt asThis toner is scraped off and collected in theoner bottle.

es can affect the registration of colors. Tose changes the temperature of the belt drivend the timing of the LED head writing is adjusted

it should be replaced approximately everyen you replace a transfer belt, you must set thee settings for temperature control. You must alsostments.head adjustments; the margin adjustment andistration adjustment. Make these adjustments in

nsfer belt is about 760 mm, and the width isbelt is conductive and has no seams. Be carefulelt or leave fingerprints on it when you replaceer remains on the belt in a scratch or on a fingerirty spots on the back side of the paper. If you doelt, wipe it off with a dry cloth or alcohol.



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5050-001

Belt Up or Down (BUD)During monochrome printing, only the black transfer anddevelopment functions operate. An electromagnetic clutch in drive 1operates to pull the transfer belt down as the paper passes underthe color PC drums. A cam on the changing shaft moves the belt upand down through gframe.

The position of theposition.


ears from the belt unit drive motor on the unit

belt is detected by a photo sensor from the cam



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5050-001

Paper Path for Mono Pages

Paper Path for Color


Pages

1-26 Service Manual

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 baseprinter cassette feeder except the optional paper feeder has its ownmotor to drive paper to the printer paper path.

Print Modes

The 3 print modes f

1. Normal mode f2. Overhead proje3. Post card mode

The modes are swi

Overhead Projector (This mode improveimage on a transpait will appear black

Service.bk Page 26 Tuesday, November 30, 1999 1:51 PMor this printer are:

or normal printing.ctor transparency mode.

tched by commands from the interface controller.

OHP) Modes the color print on transparencies. If the colorrency is not smooth, light will not penetrate it andwhen projected.

5050-001

Processing speed is reduced 75% in OHP mode. The fusertemperature is set at 20 degrees higher than normal printing. This isto improve the smoothness of the toner image by ensuring the tonermelts enough in the fuser.

When you load transparencies in the multipurpose feeder, the printerrecognizes this typemakes these adjustthe presence of tranrecommend alwaysa job to print.

Post Card Mode

In this mode the fusthe setting of transf

Clearing PaperWhen a jam occursdisplay indicates whpaper from this areaentire paper path.

After you have clearpress Go to clear thpaper from the papdisplayed, open and

The Jam Recoverythe printer reprints


of media you have loaded and automaticallyments. However, waiting for the printer to sensesparencies may further delay the job. Weselecting the correct Paper Type before sending

er temperature is also set 20 degrees higher ander voltage switches according to the humidity.

Jams, the Paper Jam message on the operator panelere to find the jammed paper. You must clear the, but you must also clear all paper from the

ed all the paper, close the printers top cover ande message. If you feel you have cleared all theer path, but the paper jam message is stillclose the top cover and press Go again.

setting in the Setup Menu determines whetherthe jammed page.

1-28 Service Manual

5050-001

When clearing a jam, open the top cover completely and clear allpaper from the entire paper path. Make sure you also clear paperjammed in the paper tray. Close the top cover and press Go.The following table lists the paper jam messages.

Printing From theBecause the multipyou must select theoperator panel or frPaper must be load

200 Paper Jam

201 Paper Jam

202 Paper Jam

24x Paper Jam

250 Paper Jam

Service.bk Page 28 Tuesday, November 30, 1999 1:51 PMMultipurpose Feeder

urpose feeder does not have auto size sensing,correct paper size and type from the printerom MarkVision before you send a job to print.ed before any paper pickup attempt is made.

Open Top Cover

Open Top CoverOpen Top Cover

Check Tray x

Check MP Feeder

5050-001

2. Diagnostic Information

The diagnostic information in this chapter leads you to the failingpart. Before you replace an entire assembly, determine if just thedefective part is available in the parts catalog. Use the error codetables, symptom tabchapter to determinfind that the removawill help you identifyappropriate tests to

If an error is displayMessage Table, StaTable and take the

If an error messageto the error messag

Part Numbers

Some of the messaof the part you are

Adjustments andReplacement

Note: When troublprint quality, always

The printer is in The OPCs are

for a color OPCcounts.

Radar Page is

Whenever you replathe required adjustmRepair Information

Service.bk Page 1 Tuesday, November 30, 1999 1:51 PMDiagnostic Information 2-1

le, service checks and the diagnostic aidse the symptom and repair the failure. You mayl procedures in the Repair Information chapterparts. After you complete the repair, perform theverify the repair.

ed, locate it in the following Service Errortus Messages Table, or Attendance Messagesappropriate action.

appears while you are working on the printer, goe table and take the indicated action.

ge tables and service checks list the part numberasked to replace.

Procedures Following Parts

e shooting, or prior to making any adustment tobe sure of the following:

stalled on a level rigid surface.never exchanged. Do not exchange a black OPC, as they will have different surface phase

always used when adjusting print registration.ce any of the following parts be sure to performents or procedures. The adjustments are in the

and Diagnostic Aids chapters.

2-2 Service Manual

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 checkedand adjusted in the LED Head Ligh Belt Thermisto Margins (Top K Printhead Adju OHP Sheet Se Counters

RIP Controller Card

If you replace the Rdrive, memory, and

Transfer Belt

Transfer belt tra Transfer belt th Printhead adju Margins (Top K

LED Printhead Contr

LED printhead Printhead adju Margins

Start

Initial Check

Before you start tro

Service.bk Page 2 Tuesday, November 30, 1999 1:51 PMservice mode.

t Quantityr Rankand C)stments (X, Y, and Theta)nsor

IP controller card be sure to move the solid stateoption cards from the old card to the new one.

ckingermistor rankstments (X, Y, and Theta)and C)

oller Board or LED Printhead

light quantitystments (X, Y, and Theta)

ubleshooting, check the following:

5050-001

Installation Environment

The power supply line voltage is plus or minus 10% of the ratedline voltage.

The machine is securely installed on a level surface in a well-ventilated place.

The room tempand the relative

Avoid sites genhumidity (nearnear open flam

Avoid sites exp

Print Paper Checks

Be sure the rec Check the pap

from a newly o

Printer MessagThe printer displaysstatus messages, aindicate a problemmessages provide iThey require no actprinter problems tha


erature is between 10 and 32C (50 and 90F)humidity between 20 and 80%.erating ammonia gas, high temperature or highwater faucets, kettles, humidifiers), cold spaces,es, and dusty areas.osed to direct sunlight.

ommended paper for this printer is being used.er for dampness. Make a trial print with paperpened package, and check the result.

es

three types of messages: service messages,nd attendance messages. Service messagesthat requires a service technician. Statusnformation about the current state of the printer.ion. Attendance messages alert the operator tot require operator intervention.

2-4 Service Manual

5050-001

Service Error Message Table

Message

900 Software Error Unrecoverable software error. Referto the operator manual.

910 Motor Error

DC Drive 1 M

918 Fan Error

Main Body F

919 Fan Error

Power Suppl

Service.bk Page 4 Tuesday, November 30, 1999 1:51 PMotor Failure

1. Be sure motor connector CN501is connected properly to the PCmotor drive (1).

2. Be sure printer controller boardconnector CN105 is connectedproperly.

3. Be sure there is no abnormal loadon the toner or drum unit.

4. Replace the toner unit or the drumunit if necessary.

5. Replace the DC motor (drive 1)(11G0256).

6. If you still have a problem, go tothe Drive 1 DC Motor ServiceCheck on page 2-28.

an Alarm

1. Be sure motor connector CN115is connected properly on theprinter controller board(11G0323).

2. Replace the fan if necessary.3. If you still have a problem, replace

the printer controller board.

y Fan Alarm

1. Be sure motor connector CN116is connected properly on theprinter controller board.

2. Replace the fan (11G0322).3. Replace the printer controller

board (11G0324).

5050-001

920 Fuser Error

Fuser Heater Trouble

1. Remove the fuser heater cablefrom the power supply (CN602)and check it for continuity. If thereis no continuity in the heater wire,

923 Fuser Error

Fuser Therm

93X 930 = Yell 931 = Mag 932 = Cya 933 = Blac

Printhead Er

939 COMM Error

Printer Contr

941 Code ROM E

Message


replace the fuser heater and thefuser oil coating roller. If there isno continuity in the thermostat, orit does not equal 240K Ohms at25 degrees C (room temperature),replace the fuser thermostat andthe fuser oil coating roller. If thethermal fuse is open, replace it.

2. If there is continuity, and thethermostat is good, replace thepower supply. If this doesnt fix theproblem, replace the printercontroller board.

istor Open

1. Be sure thermistor connectorCN119 is connected properly tothe printer controller board.

2. Short pins 1 and 2 of connectorCN119 and turn the power on.

3. If an error displays, replace theprinter controller board. If an errordoes not display, replace the fuserthermistor and the fuser oilcoating roller.

owentank

ror

1. Be sure all cables to the printheadcontroller board are correctlyseated.

2. Replace the appropriate colorprinthead and printheadEEPROM.

3. If you still have the problem,replace the printhead controllerboard (11G0555).

4. Do the printhead adjustments.See Chapter 3, Diagnostic Aids.

oller Board

Replace the printer controller board(11G0324).

rror Replace the EEPROM codecontroller, solid state drive (J10) onthe RIP control card.

2-6 Service Manual

5050-001

942 Font ROM Error Replace the EEPROM codecontroller, solid state drive (J10)(11G0607) on the RIP control card.

943 RIP ControlleError

944945946947950953954

RIP Controlle

955 NVRAM Failu

RIP Controlle

960 Memory Erro

961 Memory ErroDRAM

964 Emulation Er

Download emfailure

965 Emulation Er

Download emoutdated. Timindicate the demulation anare incompat

97X INA Failure

Message

Service.bk Page 6 Tuesday, November 30, 1999 1:51 PMr Board, Font The font and RIP controller card(11G0604) are incompatible.

r Card Error Replace the RIP controller card(11G0604). Be sure to move thesolid state drive, memory, and optioncards from the old card to the newone.

re

r Card

Replace the RIP controller card(11G0604).

r DRAM Replace memory SIMM J1 or J3 onthe RIP controller card. These mustbe in a set of 2, and must be 50 NSEDO SIMMS.

r Option Replace memory SIMM J4 or J5 onthe RIP controller card. These mustbe in a set of two, and must be 50NS EDO SIMMS.

ror

ulation CRC

Contact Technical Support forassistance.

ror

ulatione stampsownloadd RIP codeible.

Contact Technical Support forassistance.

Be sure the RIP controller riser cardand the INA are properly installed.

Replace the INA. If you still have aproblem, replace the RIP controllercard (11G0604).

5050-001

977 Network Card Error The system processor has detectedan INA is installed but cannotcommunicate with it. The X after thecard indicates which one has the

980 Switch Error

Transfer BeltDown (BUD)Problem

981 Switch Error

Abnormal FUSwitching

Message


problem. Network card 1 alwaysrefers to the INA in the bottom slotand Network card 2 always refers tothe INA in the top slot.

Be sure the RIP controller card risercard is properly installed.

or Belt Up/Sensor

1. Be sure connector CN106 isconnected to the printer controllerboard.

2. Be sure the BUD sensor actuatoris working properly.

3. Clean the BUD sensor.4. Firmly connect the connector.5. Do a sensor test. Check for

approximately +5 V on pin 2 toGND of connector CN106 as youactuate the flag in the sensor.Replace the actuator or sensor ifnecessary.

6. Replace the BUD motor unit(11G0251).

7. If you still have the problem,replace the printer controllerboard (11G0324).

/FD

1. Be sure connector CN133 isproperly connected to thecontroller board.

2. Be sure the FUD sensor actuatoris working properly.

3. Do a sensor test. Check forapproximately +5 V on connectorCN133, pin 2 to GND as youactuate the flag in the sensor.

4. Replace the FUD actuator sensor.If the sensor is good, go to thePaper Exit FU/FD Service Checkon page 2-34.

2-8 Service Manual

5050-001

983 Gear Sensor

Abnormal Gear Sensor(Color/Black)

1. Be sure CN123 and CN126 areproperly connected to the printercontroller board.

2. Clean the gear/drum sensor.

984 Gear Sensor

Abnormal DrSensor (Yello

985 Thermistor E

Belt Thermis

986 OHP Sensor

Message

Service.bk Page 8 Tuesday, November 30, 1999 1:51 PM3. Replace the drum drive gearsensor 11G0581).

If you still have the problem, go tothe Drive 1 DC Motor ServiceCheck on page 2-28.

um Gearw/Black)

1. Be sure CN125 and CN127 areproperly connected to the printercontroller board.

2. Clean the gear/drum sensor.3. Replace the drum gear sensor

(11G0581).4. If you still have the problem, go to

the Drive 1 DC Motor ServiceCheck on page 2-28.

rror

tor Open

1. Be sure the thermistor connectorunder the transfer guide isproperly connected. Also be sureCN107 is properly connected tothe printer controller board.

2. Unplug the connector and checkfor 10K ohms conductance of thebelt thermistor.

3. Replace the belt unit (11G0202).4. If you still have the problem,

replace the printer controllerboard (11G0324).

Error 1. Be sure connector CN132 isproperly connected to the printercontroller board.

2. Replace the OHP sensor.3. If you still have a problem, replace

printer controller EEPROM U107.4. If you still have a problem, replace

the printer controller board.

5050-001

992 Engine Error

Abnormal Humidity Sensor

1. Be sure connector CN121 isproperly connected to the printercontroller board. Also be sure theconnector on the humidity sensor

993 Engine ROM

Printer Contr

Message


card is plugged in correctly.2. Replace the humidity sensor

(11G0571).3. If you still have the problem,

replace the printer controllerboard.

/RAM

oller Error

1. Try to recover by turning power offand on.

2. Replace the U107 EEPROM(11G0325) on the printercontroller board.

3. If you still have the problem,replace the printer controllerboard (11G0324).

4. If you still have the problem,replace the RIP controller card(11G0604).

2-10 Service Manual

5050-001

Status Messages

Ready The printer is ready to receive and process data.

Power Saver WSdire

W

Engine Warming TPerforming Self Test T

te

Busy Tthdire

ToJoC

Waiting Twfo

Not Ready Tbem

Service.bk Page 10 Tuesday, November 30, 1999 1:51 PMhen your printer is in power saver mode, the Poweraver message replaces the Ready message on thesplay. When Power Saver is displayed, your printer isady to receive and process data.

hen Power Saver is displayed, you can:

Press Go to quick start the printer.Press Menu> or or or or or or or

5050-001

Ready Hex Hex Trace diagnostic mode is active, and the printer isready to receive data. Use Hex Trace to isolate thesource of a print job problem. With Hex Trace selected,all data sent to the printer is printed in hexadecimalanpr

ToprTon

Locking Menus Slose

Unlocking Menus Schpa

Menus Disabled Mth

Supplies AYotoreS

Maintenance Itsein

Parallel Tco

Parallel x Tco

Serial x Tco

Network x Tco

LocalTalk x Tlin

Infrared x T

Fax T


d character representation. Control code strings areinted, not executed.

exit Hex Trace mode, turn the printer off or reset theinter. To reset the printer, press Menu> or or

2-12 Service Manual

5050-001

Cancelling Job The printer is processing a request to cancel the printjob.

Resetting thePrinter

The printer is deleting any print jobs in progress andrestoring all print settings to the user defaults.

Flushing Buffer Tdi

Printing MenuSettings

Aop

ToJoC

Printing Font List Ala

ToJoC

Printing DirectoryList

Aha

ToJoC

Printing JobAccounting Stat

Are

Clearing JobAccounting Stat

Top

Restoring FactoryDefaults

T

Formatting Flash Tth

Programming Flash Tno

Formatting Disk Tpr

Service.bk Page 12 Tuesday, November 30, 1999 1:51 PMhe printer is flushing corrupted print data andscarding the current print job.list of the user default settings and the installedtions is printing.

cancel the print job, press Menu> or or or or or or

5050-001

Attendance Mess

Programming Disk The printer is storing resources on the hard disk. Donot turn the printer off while this message is displayed.

Network Card Busy The network adapter is being reset. The Network xSetup menu is not available while this message isdi

Close Top Covers Cmco

Are23

Insert Tray x InPp

Change tray TthoreiMan

To


ages

splayed.

lose the printers top cover and rear cover. If theessage will not reset, check the two actuating rodsntacting the power supply interlock switch.

ctivate the interlock switch with the power on andplace the power supply (11G0305 115 V, 11G05410 V) if the message does not reset.sert the tray indicated (tray 1, 2, or 3). Go to theaper Tray Missing/Size Service Check onage 2-35.he printer is requesting a different size or type mediaan what it detects is in the identified tray (tray 1, 2, 3,the multipurpose feeder). The message displaysther the custom media name defined using thearkVision utility, the media size, or the media sized type it is looking for.

clear the message:

If the correct paper type is loaded in the tray (but thePaper Type setting was not changed from theoperator panel), press Go to continue printing.Press Select to ignore the request and print on themedia already installed in the tray.Load media of the requested size and type in thetray indicated.If youre printing on larger paper, make sure the SizeDetection setting is correct.Cancel the print job. Press Menu> or or

2-14 Service Manual

5050-001

Load tray The printer is trying to feed paper from a source itdetects is empty (tray 1, 2, 3, or the multipurposefeeder). The message displays either the custommedia name defined using the MarkVision utility, them

To

GC

Load Manual

To

Remove PaperTop Output

Tan

Go

Service.bk Page 14 Tuesday, November 30, 1999 1:51 PMedia size, or the media size and type it is looking for.

clear the message:

Load media of the requested size and type in thetray indicated.If youre printing on larger paper, make sure the SizeDetection setting is correct.Cancel the print job. Press Menu> or or or or

5050-001

Print Jobs on Disk? Jobs that were spooled to the optional hard disk beforethe printer was last turned off have not yet printed.Press Go to print the jobs. Press Return or Stop todelete the jobs from the disk without printing them.

Files Will be Lost.Go/Stop?

YoopdicuR

Invalid Font Data Tthcopr

Invalid Network xCode

Tbevaca

30 color Print UnitMissing

TBan

33 Tray xConfiguration Error

TgulethPsi

35 Res Save OffDeficient Memory

TRinm

ToG

To


u have changed the Job Buffer Size setting from theerator panel, and the printer must reformat the hardsk to activate the change. If you press Go, all filesrrently stored on the disk will be deleted. Presseturn or Stop to cancel this operation.

he printer has detected an incompatibility betweene font data and the firmware. You must downloadmpatible font data to flash memory before theinter can return to the ready state.

he code in the specified network adapter has noten programmed or is invalid. You must downloadlid code to the network adapter before the printern return to the ready state.

he specified print unit (Cyan, Magenta, Yellow, orlack) is not installed in the printer. Insert the print unitd close the top cover to clear the message.he printer has detected a tray with the rear paperide in the wrong position. When loading A4 andtter size paper, make sure you place it in the tray withe long-edge of the sheet next to the front of the tray.osition the rear paper guide correctly for the paperze, then insert the tray in the printer.

he printer lacks the memory needed to enable theesource Save function. This message usuallydicates that too much memory is allocated for one orore of the printer link buffers.

disable Resource Save and continue printing, presso.

enable Resource Save after you get this message:

Set the link buffer for each interface to Auto, thenexit the menus to activate the link buffer changes.When the Ready message is displayed, enableResource Save from the Setup Menu.Or, install additional printer memory.

2-16 Service Manual

5050-001

37 InsufficientCollation Area

The printer memory (or optional hard disk, if installed)does not have the space necessary to collate the printjob.

38 Memory Full Tto

To

39 Complex Page Trein

To

Service.bk Page 16 Tuesday, November 30, 1999 1:51 PMPress Go to print the portion of the job alreadystored and begin collating the rest of the job.Cancel the print job. Press Menu> or or or or or or

5050-001

52 Flash Full There is not enough space available to hold theresources you want to store in flash memory.

Press Go to clear the message and continue

53 UnformattedFlash

Tbebe

Pm

54 Parallel Error Tstcom

54 Parallel Option xError

Tspcom


processing. Downloaded fonts and macros notpreviously stored in flash memory or disk aredeleted.Reset the printer. Press Menu> or or or or or or

2-18 Service Manual

5050-001

54 Serial Option xError

The printer has detected a protocol error on thespecified serial interface. Make sure the serialinterface parameters are set up correctly and you areusing an appropriate serial cable.

54 Std Par ENAConnection Lost

Acoreco

54 Par x ENAConnection Lost

Acoreco

56 Std Parallel PortDisabled

Dpoite

Service.bk Page 18 Tuesday, November 30, 1999 1:51 PMPress Go to clear the message and continueprinting. The job may not print correctly.Reset the printer. Press Menu> or or or or

5050-001

56 Parallel Port xDisabled

Data was sent to the specified parallel port, but theport has been disabled from the Parallel Buffer menuitem.

56 Serial x PortDisabled

Dha

61 Defective Disk TPYoan

62 Disk Full Tre

63 UnformattedDisk

Tfodo

Prere

ToM


Press Go to clear the message. The printer discardsthe data sent to the parallel port.Reset the printer. Press Menu> or or or or or or

2-20 Service Manual

5050-001

7079 Network Reserved for messages relating to the optionalinternal network adapter (INA) installed in your printer.For more information, refer to the onlinedocumentation included on the printer CD underN

80 ScheduledMaintenance

Tmanprinham

TcoFainun

84 Black PC LifeWarning

TapEbl

PTthmprph

Ifphse

Service.bk Page 20 Tuesday, November 30, 1999 1:51 PMetwork Printing.he printer requires replacement of routineaintenance items, such as the fuser, transport belt,d roller set to maintain top performance and avoidint quality and paper feed problems. These items area maintenance kit available from Lexmark. You mustve a trained service technician install theaintenance kit.

he message appears when the printer maintenanceunter determines 100,000 pages have printed.ilure to replace the maintenance kit items will notterrupt printer operation, but can result insatisfactory printer performance.

his message alerts you that you can printproximately 100 pages before the Black PC Drumxhausted message appears. If you do not have aack photoconductor kit, order it now.

ress Go to clear the message and continue printing.he Supplies status message is then displayed withe Ready, Power Saver, Busy and Waitingessagesunless another status message of higheriority is posteduntil you replace theotoconductor.

this message does not reset after replacing allotoconductor units, clean or replace the drumnsor (11G0550, black) in the right sub frame.

5050-001

84 Color PC LifeWarning

This message alerts you that you can printapproximately 100 pages before the Color PC DrumsExhausted message appears. If you do not have newcolor photoconductors, order them now.

Tpa

PTthmprph

Ifphse

84 Black PC DrumExhausted

T13ph

IfthstPanun

Wsuin

Ifphse


he cyan, magenta, and yellow photoconductors comeckaged together. You cannot order them separately.

ress Go to clear the message and continue printing.he Supplies status message is then displayed withe Ready, Power Saver, Busy and Waitingessagesunless another status message of higheriority is posteduntil you replace theotoconductor.

this message does not reset after replacing allotoconductor units, clean or replace the drumnsor (11G0548) in the right sub frame.he black photoconductor has reached the end of its,000-page life. You may want to replace theotoconductor now.

the print quality is still acceptable, press Go to cleare message and continue printing. The Suppliesatus message is then displayed with the Ready,ower Saver, Busy and Waiting messagesunlessother status message of higher priority is postedtil you replace the photoconductor.

hen you replace the black photoconductor, makere you also install the new fuser coating roll that iscluded in the black photoconductor kit.

this message does not reset after replacing allotoconductor units, clean or replace the drumnsor (11G0550) in the right sub frame.

2-22 Service Manual

5050-001

84 Color PC DrumsExhausted

The three color photoconductors have reached theend of their 13,000-page life. You may want to replacethe photoconductors now. When you do replace them,replace all threecyan, magenta, and yellowat thesa

IfthstPanun

Ifphse

84 color PCAbnormal

Yomca

Ifphse

88 color Toner Low Tsp25Totone

PmSstremprco

Iftose

Service.bk Page 22 Tuesday, November 30, 1999 1:51 PMme time.

the print quality is still acceptable, press Go to cleare message and continue printing. The Suppliesatus message is then displayed with the Ready,ower Saver, Busy and Waiting messagesunlessother status message of higher priority is postedtil you replace the photoconductors.

this message does not reset after replacing allotoconductor units, clean or replace the drumnsor (11G0548) in the right sub frame.u have installed a defective photoconductor. Youust replace the specified photoconductor before youn continue printing.

this message does not reset after replacing allotoconductor units, clean or replace the drumnsor (11G0548) in the right sub frame.he printer has detected that the toner supply in theecified cartridge is low. After printing approximately0 more pages, the printer will display the 88 colorner Empty message and cease operating until thener cartridge is replaced. If you do not have thecessary supplies, order them now.

ress Go to clear the message. The Supplies statusessage is then displayed with the Ready, Poweraver, Busy and Waiting messagesunless anotheratus message of higher priority is posteduntil youplace the toner cartridge. The 88 color Toner Lowessage is also displayed each time you turn theinter on and each time you open and close the topver.

this message does not reset after you replace all thener cartridges, clean or replace the toner remainingnsor (11G0207) in the right sub-frame.

5050-001

Symptom Table

88 color TonerEmpty

The printer has detected that the specified tonercartridge is completely out of toner. You must install anew toner cartridge before you can continue printing.

Ifto(1

91 Fan Error

RIP ControllerBoard Fan

1.

2.3.

2xx Paper Jam /Open Top Cover

TspTomre

YopamP

You cannot print color.

Transparencies curlexcessively.


this message does not reset after you replace all thener cartridges, replace the toner remaining sensor1G0207) in the right sub-frame.Be sure connector C193 is properly connected tothe RIP controller card.Replace the fan (11G0606) if necessary.If you still have a problem, replace the RIP controllercard (11G0604).he printer has detected a paper jam in the areaecified in the message. In some cases, the Openp Cover message alternates with the Paper Jamessage to remind you to open the top cover andmove jammed paper from inside the printer.u must remove all the paper from the entire paperth. Close the top cover and press Go to clear theessage. If the message does not clear, go to theaper Jam Service Check on page 2-30.

Make sure the Color Correction menu item is notset to Black & White.Make sure the color print units are completelyinstalled in the printer.Make sure the RIP controller card is completelyinserted in the printer and the thumbscrews aresecurely tightened.Go to the Transport Belt/BUD Service Checkon page 2-29.

Make sure youre using the recommendedLexmark transparencies. Also be sure the paperdelivery is set to the rear exit.

2-24 Service Manual

5050-001

Transparencies jam If the last transparency jams as you try to feed itfrom tray 1, place the cardboard sheet (with thecutout) included in the transparencies box in thebottom of tray 1 before loading transparencies.

The printer seemsslow to print

You cannot removepaper jammed in thefuser

You cannot clear thepaper jam message

Service.bk Page 24 Tuesday, November 30, 1999 1:51 PMIf you set Print Quality to 1200 Image Quality, itmay take longer to print some complex jobs or jobsformatted for larger paper. Select another PrintQuality setting if you need the job to print faster.If you set the Paper Type to Transparency or CardStock, the printer increases the fuser temperatureand slows printing to 3 ppm to improve the printquality. After printing on these media, the printerrequires additional time to cool the fuser after youselect another Paper Type setting (such as PlainPaper or Letterhead).If Printer Usage is set to Maximum Yield, theprinter must adjust the photoconductors as itprepares to print a color page after printing a monopage. The printer performs this same calibrationeach time you turn the printer on and each timeyou open and close the top cover. Depending onthe types of jobs you print, these adjustments maysignificantly slow print time.Setting Timing Adjustment to Gear Only maydecrease the time necessary to complete thecalibration, but you may notice inconsistent colorregistration on your printed pages.

Make sure the printers top cover is completelyopen. Opening the top cover all the way releasesthe fuser roll so you can easily remove jammedpaper.Go to the Paper Carrying Service Check onpage 2-32.

To clear the paper jam messages, you mustremove all paper from the printers paper path.Check both inside the printer as well as the papersource you were using. Open and close the topcover and press Go. If the message does not clear,go to the Paper Jam Service Check onpage 2-30.

5050-001

Paper jam in pick-upassembly

Go to the Paper Carrying Service Check onpage 2-32.

Fuser failure Go to the Fuser Service Check on page 2-27.

No paper pick-up frommultipurpose tray

No paper pick-up fromupper or lowercassette.

Registration rollerdoes not rotate.

Operator panel doesnot operate properly

Foggy print

Black pages

Blank print

White spots

Poor reproduction

Incorrect color imageregistration

Dirt on back of paper

Low image density

White and black linesand bands


Go the Paper Carrying Service Check onpage 2-32.

Go to the Optional Paper Feed Service Checkon page 2-30.

Go to the Drive 1 DC Motor Service Check onpage 2-28.

Go to the Diagnostic Aids chapter and run the LCDand Button tests. If the tests fail, replace theoperator panel (99A0001). If the diamonds remain,check the pairs of SIMMs in J1 and J3, and theriser card (11G0605) for proper installation. If youstill have the problem, replace the operator panel.If this does not fix the problem, replace the ROMsolid state drive (11G0607). If you still have aproblem, replace the RIP controller card(11G0604).If your machine beeps 5 times and the screen isblank or all diamonds, replace the operator panel.

Go to Print Quality Problems on page 2-38.

2-26 Service Manual

5050-001

Evenly spaced markson the paper, or asingle mark in thesame place on everypage.

Go to the Marks on Paper Service Check onpage 2-37.

Poor fusing

Toner scatter on frontor back of paper

Paper Jam 201 clearsbut the fuser and exitrollers do not rotatewhile the printerresets.

Paper will not feedfrom MPF

Service.bk Page 26 Tuesday, November 30, 1999 1:51 PMGo to the Fuser Service Check on page 2-27.

Check the following:

Excessive toner buildup. Clean off the toner andrun a test print.

Transfer belt assembly

Transfer belt toner waste bottle

Fuser separation pawl

Go to the Drive 2 Stepper Motor ServiceCheck on page 2-29.

Be sure you have paper in the MPF

Be sure the MPF paper present sensor connector(CN110) is connected to the printer controllerboard.

Do a sensor test. Check for approximately +5 Vbetween pin 2 and Gnd on connector CN110 asyou actuate the flag to the sensor. Replace theparts as necessary.

If the paper still does not feed, go to the PaperCarrying Service Check on page 2-32

5050-001

Service Checks

Fuser Service Check

When you work on the fuser be sure to reposition it to the originalmounting position. Aare not damaged w

1 FuserHeater

FuserThermostat

FuserThermalFuse

2 Power Supply

3 FuserThermistor

PrinterControllerBoard

4 Springs

5 Fuser Roll Press Roller

6 SeparationPawl

DetachFingers

7 Fuser position


lso be sure the exit sensor and FUD sensorshen you replace the fuser.

The fuser may not be fusing correctly or not fusingat all.

Disconnect the fuser heater cable CN602 from thepower supply. Check for continuity of the heater(11G0348 115 V, 11G0549 230 V), thermostat(11G0349), and thermal fuse. The thermostat mustequal 240K Ohms at 25 degrees C (roomtemperature).Replace the failing part.

With the paper exit cover interlock activated, checkfor approximately 120 V or approximately 240 V onconnector CN602 pin 1 and 2.

Be sure connector CN119 is securely pugged intothe printer controller board.

If the problem remains, unplug connector CN119and short pins 1 and 2 on the connector togetherwith the power on. If an error code displays, replacethe printer controller board. If no error displays,replace the Thermistor (11G0353).Be sure the two large springs that hold the fuserrollers together are securely in place.

Be sure the fuser roll and the press roller are notdirty or damaged. Replace as necessary.

Be sure the detach fingers are not dirty, damaged,or out of position. Replace as necessary.

Be sure the fuser mounting guides are adjusted forproper paper exit tracking. Replace as necessary.

2-28 Service Manual

5050-001

Color Print Unit Missing Service CheckWhen you replace the PC drum unit, all three color units must bereplaced at the same time.

Drive 1 DC Motor

1 Color PrintUnit

2 Right SideSub-frame Unit

3 High VoltageUnit 1

4 High VoltageUnit 2

5 PrinterControllerBoard

1 DC Motor Drive Unit 1 PrinterControllerBoard

Service.bk Page 28 Tuesday, November 30, 1999 1:51 PMService Check

Check for dirt or damage to the sensing contacts onthe right side of the cartridge assembly. Clean orreplace the PC drum unit if necessary. The tonerand PC drum unit must be installed as a unit.

Check the sensing contacts on the right side sub-frame assembly. Clean or replace the affected rightside sub-frame.

If you still have the problem, replace the highvoltage unit 1(11G0326).If you still have the problem, replace the highvoltage unit 2 (11G0313).If you still have the problem, replace the printercontroller board (11G0324).

If the motor does not attempt to turn and youreceive a 910 error code, replace the driver 1 dcmotor (11G0256).Be sure the toner and dc drum units are notcausing an overload on the dc motor.

If the motor turns but the paper carrying section ofthe machine does not rotate, check the drive 1 unitgear train for damage. Be sure the clutch on thegear train engages for color printing. Replace thedrive 1 unit if necessary (11G0257).If this does not correct the problem, replace theprinter controller board (11G0324).

5050-001

Drive 2 Stepper Motor Service Check

Transport Belt/BU

1 Drive 2Stepper Motor

Be sure connector C112 on the printer controllerboard is firmly connected. If you still have the

2 Drive 2Stepper MotorUnit

1 BUDSensors

BUDActuator

2 BUD Motor

3 BUD Lift Cams

4 PrinterControllerBoard


D Service Check

problem, replace the drive 2 stepper motor(11G0260).If the drive 2 stepper motor rotates and the fuser,and exit rolls do not rotate, replace the drive 2stepper motor unit (11G0258).

Check the transfer belt BUD sensor. Replace thesensor or the actuator if necessary.

Be sure connector CN106 is firmly connected.Replace the BUD unit if necessary (11G0254).Check and replace the BUD lift cam shaft ifnecessary (11G0267).If you still have the problem, replace the printercontroller board (11G0324).

2-30 Service Manual

5050-001

Optional Paper Feed Service Check

If you have a 24XX error code, the last number in the code indicatesthe affected tray.

Check the option connection cable for proper connection to theprinter or other pap

If you have two optione directly to the p

Paper Jam Servic

Be sure the custom

If the machine is tu250 is displayed, doService Check.

You must clear all pthe top cover and therror, run a single scode and the positicode from the follow

Jam 200

Check the paper re(flag) and look for aconnector CN110 oapproximately +5 V

1 Drive Motor

2 Gears

Service.bk Page 30 Tuesday, November 30, 1999 1:51 PMer feeder.

onal feeders, you can connect the non-workingrinter to check for a cable or drive card problem.

e Check

er is using the correct paper.

rned on and error code 200, 201, 202, 24X, orthe following before going to the Paper Carrying

aper from the entire paper path. Open and closee rear cover then press Go. If you still get anheet of paper through the machine, note the erroron of the paper in the printer. Locate the erroring and check parts as indicated.

gistration sensor by actuating the sensor leverchange of voltage at pin 2 to ground onn the printer controller board. Look for. If it works properly go to the Paper Carrying

If the drive motor works, go to the Paper CarryingService Check on page 2-32.

If the drive motor does not work, check for 8 Ohmsresistance between pins 1 to 3, and 2 to 4. Replacethe motor if necessary (11G0414).If the motor turns but the drive gears do not,replace the gears as necessary. If this does notcorrect the problem, replace the optional feed driverboard.

5050-001

Service Check on page 2-32. If it does not work properly, replacethe actuator or sensor. If that doesnt correct the problem, replacethe printer controller board.

Jam 201

Remove the cartridexit sensor. Actuatevoltage at pin 2 to gprinter controller boproperly go to the If it does not work pdoesnt correct thethe fuser exit rollersService Check on

Jam 202

Check the paper exlooking for a changCN124 on the printIf it works properlypage 2-32. If it doesensor. If that doescontroller board.

24X Paper Jam

Be sure the option pto the Paper Carry

Paper Jam

Be sure there is nothe Paper Carryin


ges. Check the registration sensor and the paperthe sensor lever (flag) and look for a change ofround on connectors CN110 and CN124 on theard. Look for approximately +5 V. If it worksPaper Carrying Service Check on page 2-32.roperly, replace the actuator or sensor. If thatproblem, replace the printer controller board. Ifdo not turn, go to the Drive 2 Stepper Motorpage 2-29.

it sensor by actuating the sensor lever (flag) ande of voltage at pin 2 to ground on connectorer controller board. Look for approximately +5 V.go to the Paper Carrying Service Check ons not work properly, replace the actuator ornt correct the problem, replace the printer

aper tray 2 and 3 are plugged in correctly and going Service Check on page 2-32.

paper jammed in the MPF, then go to step 1 ofg Service Check on page 2-32.

2-32 Service Manual

5050-001

Paper Carrying Service CheckThe paper is being picked up and carried to the registration roll.

1 Paper SizeGuide

SideLocationPlates

2 Paper FeedRoller(MPF)

Paper FeedRolls (MPFtray 1, 2,3)

CarryingRoller (Tray1, 2, 3)

FrictionStopPad (MPF)

3 Gears

4 Paper FeedSolenoid

Paper FeedClutch

Service.bk Page 32 Tuesday, November 30, 1999 1:51 PMBe sure the paper cassette has the size guides andthe side locator locks are working properly.

Replace parts as necessary.

Be sure the paper feed rollers are free of dirt andnot damaged.

Be sure the stop friction pad is free of dirt and notdamaged.

Replace parts as necessary.

Be sure the paper feed gears are not damaged.

Be sure the paper feed solenoid activates the paperfeed clutch and the clutch engages properly.

Check the failing paper feed solenoid for continuity.Also check connector CN101 and CN102 (MPF) onthe printer controller board and CN906 on theoption paper feed driver board.

5050-001

The paper has stopped at the registration roller or has not reachedthe fuser.

If the fuser or exit rollers do not turn during POR, go to the Drive 2Stepper Motor Service Check on page 2-29.

1 RegistrationRollerClutch

RegistrationRoller

AbsorptionRoller

Transfer BeltUnit

Rear PaperFeed Guide


Check these parts for wear or damage. Replace asnecessary. Be sure all guide surfaces in the paperpath are free of dirt.

Check the registration roller clutch for continuity.

Be sure connector CN104 on the printer controllerboard is connected properly.

2-34 Service Manual

5050-001

The paper has exited the registration roll and entered the fuser.

The paper has entere

Paper Exit FU/FD

1 Transfer BeltUnit

Rear PaperGuide

DischargeBrush

Fuser Roller Fuser PressRoller

Remove any buildup of toner. Replace anddamaged or worn parts.

2 FuserSeparationPawl

1 Fuser Roller Fuser PressRoller

FuserSeparationPawl

2 Fuser ExitLower roller

Exit Guide FU/FD FlapSolenoid

Exit FlapClutch Lever

Gears Fuser ExitUpper Roller

1 FU/FD SensorActuator

Service.bk Page 34 Tuesday, November 30, 1999 1:51 PMd the fuser and exited the printer.

Service Check

Be sure the separation pawls do not have any tonerbuilt up on the tips. Replace any damaged or wornparts.

Remove any toner buildup and replace any worn ordamaged parts.

Be sure the exit FU/FD solenoid energizes in thecorrect position for either face down or face updelivery. Replace any damaged or worn parts.

Do a continuity check of the solenoid. Be sureconnector CN122 is properly connected to theprinter controller board.

If the paper is not exiting to the back paper face uptray or the face down tray, check the sensors.

5050-001

Paper Low/Empty

Paper Tray Missin

2 Flap Check the paper flap (vane) that directs the paperto the proper tray. Replace if necessary.

3 FU/FDSolenoid

Check the FU/FD solenoid for continuity. Also besure connector CN122 is properly connected to theprinter controller board.

4 Gear Cam

1 Actuator Sensor

1 Actuator Sensor

2 Paper SizeDetectionBoard


Tray 1, 2, 3 Service Check

g/Size Service Check

Check the gears and the metal actuating cam forwear or damage. Replace as necessary.

Check the actuators and sensors for properoperation.

Tray 1 = connector CN106 pin 9, and pin 12 toGND

Tray 2 and 3 = CN903 pin 2, and pin 5 to GND

Check the paper size indicator for proper operation.

Check the size detection fingers for properoperation. Replace parts as necessary.

Do a sensor check for the paper size detectionboard. It should be approximately +5 V whenactivated.

Tray 1 = CN108 pins 11, 12, and 13 to GND Tray 2 and 3 = CN904 pins 1, 2, and 3 to GND

If you still have a problem, replace the paper sizedetection board (11G0310).

2-36 Service Manual

5050-001

Remove Paper Sensor Service Check

Power Supply Ser

1 Remove PaperLever

Check the operation of the paper full lever andactuator shaft. Replace as necessary.

2 Paper FullSensor

1 Voltage

2 Power Cord

3 Fuse Switch

4 Power Supply

Service.bk Page 36 Tuesday, November 30, 1999 1:51 PMvice Check

Check the sensor for operation. Check forapproximately +5 V from CN109 pin 2 to GNDwhen the sensor is activated. Replace if necessary.

Be sure the switch is on and the power cord isfirmly plugged into the printer. Be sure the correctvoltage is present at the outlet.

Check the power cord for continuity.

The power supply fuses may be blown. Unplug themachine and check fuse F

Documents

1200 COLOR Service Manual.PDF