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Service Manual

Lexmark S800 Series All-In-One

Machine Type 4310-VWx

Edition: April 1, 2011

The following paragraph does not apply to any country where such provisions are inconsistent with local law:

LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,

EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or

implied warranties in certain transactions; therefore, this statement may not apply to you.

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information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the

programs described may be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22X/002-1, 740 West New Circle Road,

Lexington, Kentucky 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any

of the information you supply in any way it believes appropriate without incurring any obligation to you.

References in this publication to products, programs, or services do not imply that the manufacturer intends to make these

available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or

imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that

does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in

conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the

user’s responsibility.

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States

and/or other countries.

All other trademarks are the property of their respective owners.

© 2010 Lexmark International, Inc.

All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer software

and documentation developed exclusively at private expense.

P/N 12G0468 Rev 001

Lexmark S800 Series

Table of contents iii

Lexmark S800 Series

Table of contents

Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Print specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Scanner (image capture) specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Fax specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Copy specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Media specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Understanding the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Using the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Power-On Self Test (POST) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Theory of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Print engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13System board service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Carrier service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Test page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Uninstall/reinstall instructions for Windows users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

For Windows 2000, Windows XP, Windows Vista, and Windows 7 . . . . . . . . . . . . . . . . . . . . . . 3-1

Uninstall/reinstall instructions for Mac users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Uninstall/reinstall instructions for Linux users . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Uninstallation for DEB-based package: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Uninstallation for RPM-based package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Duplex and rear fax/phone cables cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Right side cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Left side cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Inner front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Lower front door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Front door/operator panel/camera assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Camera assembly with front door and operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

USB connector and cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18Fax card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Exit tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Table of contents iv

Lexmark S800 Series

System board with media sensor, cable, and spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Star wheel cross bar assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Bottom power supply cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23Wireless (INA) card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Print engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Rear/inside views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Base view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

System board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

System board connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Preventive maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Safety information v

Lexmark S800 Series

Safety information

• The safety of this product is based on testing and approvals of the original design and specific

components. The manufacturer is not responsible for safety in the event of use of unauthorized

replacement parts.

• The maintenance information for this product has been prepared for use by a professional service person

and is not intended to be used by others.

• There may be an increased risk of electric shock and personal injury during disassembly and servicing of

this product. Professional service personnel should understand this and take necessary precautions.

Consignes de sécurité

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume

aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de

maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel

d'entretien qualifié devra prendre toutes les précautions nécessaires.

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti

specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle

parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di

assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza

autorizzato deve, quindi, adottare le precauzioni necessarie.

Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und

bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine

Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines

elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende

Vorsichtsmaßnahmen treffen.

CAUTION: POTENTIAL INJURY

This device contains a lithium battery. There is a danger of explosion if a lithium battery is

incorrectly replaced. Replace it only with the same or equivalent type of lithium battery.

Discard used batteries according to the manufacturer’s intstructions and local regulations.

Safety information vi

Lexmark S800 Series

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes

específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no

autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal

cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de

la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones

necesarias.

Informações de Segurança

• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes

específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição

não autorizadas.

• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não

devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.

Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

Informació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components

específics.

El fabricant no es fa responsable de les qüestions de

seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està

destinada

a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei

d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre

les mesures convenients.

Safety information vii

Lexmark S800 Series

Preface viii

Lexmark S800 Series

Preface

This manual contains maintenance procedures for service providers. It is divided into the following chapters:

1. General information contains a general description of the printer and the maintenance approach used to repair

it. It includes printer specifications, special tools, and acronyms.

2. Diagnostic information contains an error code table, symptom tables, and service checks used to isolate failing

field replaceable units (FRUs).

3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems.

4. Repair information provides instructions for making printer adjustments and removing and installing FRUs.

5. Connector locations uses illustrations to identify the connector locations and test points on the printer.

6. Preventive maintenance contains the lubrication specifications and recommendations to prevent problems.

7. Parts catalog contains illustrations and part numbers for individual FRUs.

General information 1-1

Lexmark S800 Series

1. General information

The Lexmark™ S800 Series All-In-One (4310-VWx) is a letter-quality printer with the ability to copy, scan, and fax.


Lexmark S800 Series

Print specifications

Print speed Quick print: 33 ppm mono / 30 ppm color

Print functions/features Standalone photo printing:

• Color or black (grayscale) photo printing

• Photo Menu options pop up at card insert

• Print all photos

• Save photos to PC

• Print DPOF selection via PictBridge or card

• Print from PictBridge camera

• Red eye reduction via operator panel

• Photo effects: Auto image enhance, antiquing (gray or brown), sepia, black and white

• Autoprint

• PictBridge with n-up support

• Copy from memory card to USB drive

• Photos over network

Card reader support • Multi Media Card (MMC)

• Secure Digital (SD)

• Mini SD (with customer supplied adapter)

• Memory Stick (MS)

• Memory Stick Pro

• Memory Stick Duo (with customer supplied adapter)

• Memory Stick Duo Pro (with customer supplied adapter)

• XD

• XD type M and H

• Micro SD (Transflash) (with customer supplied adapter)

• MMC mobile (with customer supplied adapter)

• RS-MMC (with customer supplied adapter)

• SDHC (high capacity)

Card reader location Right side panel


Lexmark S800 Series

Scanner (image capture) specifications

Image Capture Device (ICD) • 10 megapixel monochromatic image sensor

• Up to 30 megapixel image capture

Imaging modes True color:

• 36 bits internal

• 24 bits external

Gray mode:

• 36 bits internal

• 8 bits external

Text/line art:

• 1 bit per pixel

ICD area 8.5 x 11.7 inches (216 x 297 mm)

ICD resoluation hardware maximum (flatbed)

300 x 300 ppi

Image capture quality Selectable via driver

Available options

Flash to memory card

Yes No

x

Flash to email x

Smart Copy x

Video preview x

Instant preview x


Lexmark S800 Series

Fax specifications

Fax type Standalone mono and color fax

Paper size Send: letter and A4

Receive: legal, letter and A4

Fax resolution Mono and color support initiated via operator panel:

• Standard: 100 x 100 ppi

• Fine: 200 x 200 ppi

• SuperFine: 300 x 300 ppi

• Ultra fine: 400 x 400 ppi

Fax features • TAD (telephone answering device) hookup

• Speaker (no microphone)

• 89 speed dials, 10 group calls

• 30 fax numbers per group supported

• 64 digit fax number support

• Caller ID (where supported)

• Automatic redial/busy redial

• Call waiting disable support

• Fax/tel mode with distinctive ring detection

• Confirmation, error, and activity reports

• Up to 160 pages using standard resolution

• Pulse/tone mode

• Delay send

• Broadcast send

• Fax forwarding

• Fax forwarding and print

• Junk fax block (where available)

• Auto answering

• Print to fax function

• Parallel handset detection support

• Parallel handset manual pickup support

• Digital line detect and notify

• Group fax

• VOIP compatible fax


Lexmark S800 Series

Copy specifications

Copy function Standalone only

Standalone copy speed Quick copy:

First copy: 8 ppm mono target, 3 ppm color

Additional copies: 25 ppm mono, 21 ppm color

Standalone copy specifications Mono copy:

• Quick: 300 X 600 dpi print, 300 X 300 ppi scan

• Normal: 600 X 600 dpi print, 300 X 300 ppi scan

• Photo: 1200 X 1200 dpi print, 300 X 300 ppi scan

Color copy:

• Quick: 300 X 600 dpi print, 300 X 300 ppi scan

• Normal: 600 X 600 dpi print, 300 X 300 ppi scan

• Photo (plain): 1200 X 1200 dpi print, 300 X 300 ppi scan

• Photo (glossy): 1200 x 1200 dpi print, 300 x 300 ppi scan

Standalone copy features • Reduction/enlargement (25%-400%)

• Copy to selected paper sizes

• Light/dark control (slide bar)

• Multiple copies (1-99)

• Fit to page

• Repeat image N-up

• Collate

• Manual duplex copy

• Poster (host and standalone):

• Minimum: 4 pages

• Maximum: 16 pages

• Borderless copy selectable via printer driver (on all sizes listed below, excluding 3 x 5 and B5)

Standalone media type (for printed output)

• Plain

• Matte

• Photo

• Transparency

• Lexmark Photo

• Lexmark PerfectFinish Photo


Lexmark S800 Series

Media specifications

Paper capacities Input tray

Plain paper Up to 100 sheets

Envelopes Up to 10 envelopes

Banner Up to 20 sheets

Heavy weight matte Up to 25 sheets

Photo/glossy Up to 25 sheets

Transparencies Up to 50 sheets

Iron-on transfer Up to 10 sheets

Card stock Up to 25 sheets

Labels Up to 25 sheets

Exit tray

Plain paper Up to 50 sheets

Transparencies 1 sheet

Photo/glossy 1 sheet

Labels Up to 20 sheets

Envelopes Up to 10 envelopes

Heavy weight matte Up to 25 sheets

Banner Up to 20 sheets

Iron-on transfer Up to 10 sheets

Card stock Up to 15 sheets

Paper handling • L-path

• Out of paper detection via media sensor


Lexmark S800 Series

Media sizes (via driver) Automatic sheet feed:

• Letter (8 1/2 x 11 in.)

• Legal (8 1/2 x 14 in.)

• Executive (7 1/4 x 10 1/2)

• 4 x 6 in.

• 4 x 8 in.

• 10 x 15 cm

• 10 x 20 cm

• A4 (210 x 297 mm)

• B5 (182 x 257 mm)

• A5 (148 x 210 mm)

• A6 card (105 x 148 mm)

• Hagaki (100 x 148 mm)

• 5 x 7 in.

• 13 x 18 cm

• Letter banner

• A4 banner

• Custom size (width 4-8.5 in., height5.0-14.0 in.)

Envelopes:

• 7 3/4

• #9

• #10

• DL

• C5

• C6

• B5

• A2 baronial

• 6 3/4

• Custom size

Japanese envelopes:

• Chokei 3 - 120 x 235 mm

• Chokei 4 - 90 x 205 mm

• Chokei 40 - 90 x 225 mm

• Kakugata 3 - 216 x 277 mm





Lexmark S800 Series

Supported media sizes (standalone) • Letter

• Legal

• 4 x 6 in.

• 4 x 8 in.

• 5 x 7 in.

• A4

• B5

• A5

• A6

• Hagaki

• 10 x 15 cm

• 10 x 20 cm

• 13 x 18 cm

Borderless media support Via host:

• Letter

• Legal

• A4

• B5

• A5

• A6 card

• 4 x 6 in.

• 10 x 15 cm

• 5 x 7

• 13 x 18 cm

• Hagaki

• 4 x 8

• 10 x 20 cm

Standalone:

• 4 x 6

• 4 x 8

• 5 x 7

• Letter

• A6

• A5

• A4

• Hagaki

• 10 x 15

• 10 x 20

• 13 x 18

Duplex • Supported media sizes: letter and A4

• Supported media types: 20 and 24 pound plain (80 to 90 grams)

• No borderless duplex capacity


Lexmark S800 Series

Understanding the operator panel

Using the operator panel

The operator panel functions allow you to copy, scan, fax, or print documents and photos. The operator panel features:

• Power button on front panel (white LED)

• 4.3” touchscreen WQVGA display with screen saver, functions via touching


Lexmark S800 Series

Number Part LED/icon Function

1 Back • Returns to the previous screen

• Exits from one menu level to a higher one

2 Touchscreen Display • Navigates the printer menus

• Changes settings

• Views printer messages and animation

Note: The display is turned off in Power Saver mode.

3 Home Returns to the home screen

4 Help Views Help text messages

5 Cancel button Cancels the current job or task

6 Start button Starts a print, scan, fax, or copy job, depending on which mode is selected.

7 Power on/off button • Turns the printer on and off

• Switches to Power Saver mode

Note: When the printer is on, press the Power button to switch to Power Saver mode. Press and hold the Power button for three seconds to turn off the printer.


Lexmark S800 Series

Maintenance approach

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error

codes, symptom tables, service checks, and diagnostic aids to determine the symptom and repair the failure.

After you complete the repair, perform tests as needed to verify the repair.

Tools required for service

• #1 Phillips screwdriver

• #2 Phillips screwdriver

• Spring hook

Acronyms

dpi Dots per inch

DSA NPA Device Status Alert

EEPROM Electrically Erasable Programmable ROM

EOF End of Form

Flash Fast EEPROM

ICD Image Capture Device

LED Light-Emitting Diode

NPA Network Printing Alliance

NVRAM Nonvolatile Random Access Memory

POR Power-On Reset

POST Power-On Self Test

ppi Pixles per inch

ROM Read Only Memory

TSR Temperature Sense Resistor

USB Universal Serial Bus

2-1 Service Manual

Lexmark S800 Series

2. Diagnostic information

Power-On Self Test (POST) sequence

Plug the All-In-One into an electrical outlet. The printer comes on automatically.

The All-In-One does a Power-On Self Test (POST) sequence.

1. The Power button, Copy button, and Color button lights come on.

2. The following will be displayed on the LCD screen sequentially:

Lexmark, Energy Star, and a bar indicating the remaining time for POST.

3. The purge pump runs simultaneously, and then shuts off.

4. The carrier moves off of the maintenance station simultaneously, and then returns.

5. Home Menu appears on the LCD screen with functional icons.

If any of these fail to occur, remove and reinstall the print cartridge, and then repeat the POST. If the POST remains

incomplete, then see “Service checks” on page 2-13. Find the symptom, and take corrective action.

Theory of operation

The printhead system consists of a single ½”chip with 640 nozzles per color. The ink is supplied and stored in individual

felt-filled ink tanks. Upon installation of the tanks, the ink must be drawn from the tanks to the printhead chip. This is

accomplished by activating the pump to create a vacuum in the maintenance cap. The vacuum is held until all air is

purged from the ink system.

Media is loaded into the input tray where it is restrained by the friction buckler. The edge guides are adjusted to center

the media and ensure that it sits squarely in the tray. The media sensor detects media type (plain, photo, coated,

transparency) or paper-out. When a print job is received by the printer, an authentication and maintenance operation is

invoked. During this operation, the validity of the tanks and the ink level in each tank are verified by the RFID system.

The printhead is then prepared for printing by wiping the surface of the chip and activating each nozzle.

The printing operation is initiated as the pick roll, which is driven by the pick motor, applies a lateral force to the top

sheet of the media. This force overcomes the resisting force of the friction buckler, allowing the single sheet to be

separated from the remaining media stack. The pick roller moves the media sheet to the feed roller, which hesitates to

rotate until sheet is squared with nip. This corrects for skew. The pick roller is de-energized and now the feed roller

advances the media to the print zone. The printed image is applied in horizontal swaths as the carrier drives the

printhead across the page. Successive swaths are overlaid by repeatedly incrementing the feed roller a set distance

between print swaths. The printed media is driven out of the print zone by a nip formed by a driven exit roller and fine-

pointed starwheels.

If a duplex print job is selected, the media is not fully exited from the machine after the first side is printed, but is driven

just far enough to clear the upper duplex gate. At this point the pick motor is driven in reverse which lifts the upper

duplex gate. The feed roller is then driven in reverse and the media is fed into the duplex guides where it is driven by

the duplex roller. After the page is rotated in the duplexer, it arrives back at the now forward-rotating feed roller and the

second side is printed.

Diagnostic information 2-2

Lexmark S800 Series

Print engine

Paper path

2-3 Service Manual

Lexmark S800 Series

Troubleshooting tables

The All-In-One has the capability to report internal errors. This is accomplished by displaying the error code on the

operator panel LCD. Also, some errors are reported to host through Extended NPA Device Status Alert (DSA). See

Consumer Printer Division Host-Printer Communications Specification for more details on NPA and DSA.

There are four classes of All-In-One errors:

• POST errors

• Catastrophic unrecoverable errors

• Paper handling errors

• Printhead errors

Note: Each error will have a unique, 4-digit code.


Lexmark S800 Series

Error Code Table

Error

CodeName Description Action

08 Print Carrier Stall The All-In-One carrier has stalled.

Technical Support Center:

Clear the carrier jam, and resend the print job.

Service:

See “Carrier service checks” on page 2-14.

0101 Paper Out The All-In-One is out of paper. Technical Support Center:

Load paper.

Service:

Load paper. If the problem remains, then check the paper sensor; if the paper sensor is ok, then check and/or replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21.

0102 Paper Jam There is paper jammed in the All-In-One.


Clear the paper jam, and resend the print job.

Service:

Clear the paper jam, and resend the print job. If the problem remains, then check the All-In-One for foreign objects.

0108 Carrier Jam The carrier is jammed and will not move.


Check the All-In-One for foreign objects.

Service:


0109 Carrier Jam The carrier is jammed and will not move.


Check the All-In-One for foreign objects.

Service:


010A Carrier Jam The carrier is jammed and will not move.


Service:


2-5 Service Manual

Lexmark S800 Series

010B Printhead Error The printhead has an error. Technical Support Center:

Reinstall the print tanks. If the error is still there, then replace the print tanks. Check the printhead contacts to be sure that they are clean.

Service:

Reinstall the print tanks. If the problem remains, then clean the contacts on the printhead. If the problem persists, then replace the printhead.

0302 NVRAM R/W An error was detected in reading or writing NVRAM.


Replace the All-In-One.

Service:

Replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21.

0303 Memory Failure Unable to initialize memory. Technical Support Center:


Service:


0304 Hardware Failure General hardware failure (unable to localize failure to a specific system).



Service:


0305 ROM_Checksum_Failure Corrupted ROM. Technical Support Center:

Unplug the All-In-One from the wall outlet; wait a few seconds, then plug the All-In-One back in and turn the power on.

Service:


0306 Paper System Failure The DC paper feed system fails to initialize or calibrate.


Unplug the All-In-One from the wall outlet; wait a few seconds, then plug the All-In-One back in and turn the power on.

Service:


Error



Lexmark S800 Series

1100 Paper Jam There is paper jammed in the All-In-One.



Service:


1101 Paper Out The All-In-One is out of paper. Technical Support Center:

Load paper.

Service:

Load paper. If the problem remains, then check the paper sensor.

1102 Incorrect Printhead Printhead ID is not valid. Technical Support Center:

Replace the printhead with the correct printhead.

Service:

Replace the printhead with the correct printhead.

1103 Missing Printhead Printhead is missing. Technical Support Center:

Install a printhead.

Service:

Install a printhead.

1104 Printhead Order Unsupported order of printhead.


Install the correct printhead.

Service:

Install the correct printhead.

1105 Scan Back Alignment Failure Automatic alignment has failed. Technical Support Center:

Follow the instructions on the computer screen to recover and align the print tanks.

Service:

Follow the instructions on the computer screen to recover and align the print tanks.

Error


2-7 Service Manual

Lexmark S800 Series

1201 Print Incomplete The print carrier stopped before all of the data was used.


Clear any carrier jams. Unplug the All-In-One from the wall outlet, wait a few seconds, then plus the All-In-One back in and turn the power on. Resend the print job.

Service:

Clear any carrier jams. Unplug the All-In-One from the wall outlet, wait a few seconds, then plus the All-In-One back in and turn the power on. Resend the print job.

1202 Data Error Incorrect data has been sent from the host computer to the All-In-One.


Unplug the All-In-One from the wall outlet; wait a few seconds, then plug the All-In-One back in and turn the power on. If the problem remains, then replace the USB cable.

Service:


1203 Printhead Short The short test detected a short circuit in the printhead.


Remove the printhead. Clean and reinstall the printhead. If this does not correct the problem, then replace the printhead.

Service:

Remove the printhead. Clean and reinstall the printhead. If this does not correct the problem, then replace the printhead.

1204 Printhead Programming Firmware is unable to program pseudo-random printhead ID.


Replace the printhead.

Service:


1205 Mono TSR Error There is a problem in the color TSR circuit; cannot determine printhead temperature.



Service:


1206 Color TSR Error There is a problem in the color TSR circuit; cannot determine printhead temperature.



Service:


Error



Lexmark S800 Series

1207 Paper System Error A paper system error control failure was detected.


Clear the paper path. Unplug the All-In-One from the wall outlet; wait a few seconds, then plug the All-In-One back in and turn the power on. If the remains, then replace the All-In-One.

Service:


1208 Printhead Memory Error Firmware is unable to read the printhead’s memory.


Clean the contacts. If the problem persists, then replace the printhead. If the problem remains, then replace the All-In-One.

Service:

Replace the printhead. If the problem remains, then replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21.

1209 FLASH Programming Error Could not program FLASH. Technical Support Center:

The printer will auto reset. If the problem remains, then replace the All-In-One.

Service:


1210 Mode Select An invalid print mode was selected in the print command.


Resend the print job. If the problem remains, then reinstall the printer driver.

Service:

Resend the print job. If the problem remains, then reinstall the print driver.

1211 USB Error An error was detected in USB hardware, or invalid results occurred in USB code.



Service:

Replace the USB cable. If the problem remains, then replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21.

Error


2-9 Service Manual

Lexmark S800 Series

1212 Watchdog Error Indicates printer system was reset by Watchdog timer; Subsystem stall failure.



Service:


1213 Data Abort Error Firmware attempted to load or store to an invalid address.



Service:


1214 Invalid Processor Mode Error Indicates the ARM processor was in an incorrect mode to perform the requested operation.



Service:


1215 Math Error There is a problem doing math, such as dividing by zero.



Service:


1216 Mailbox Error Problem with the internal mailbox messaging system.


The printer will auto reset.

Service:


Error



Lexmark S800 Series

1217 Printhead Temperature Error There is a problem determining temperature.


Check and clean the contacts. If the problem persists, then replace the printhead.

Service:

Check and clean the contacts. If the problem persists, then replace the printhead.

1218 Serial Flash Error Invalid parameters have been passed to ReadFlashPage.


Unplug the All-In-One from the wall outlet; wait a few seconds, then plug the All-In-One back in and turn the power on. If the problem remains, then replace the All-In-One.

Service:


1219 Undefined Signal Error Microprocessor has encountered a bad signal (other than an abort, illegal instruction, or arithmetic exception).



Service:


120A Undefined Error The microprocessor has encountered an abort or undefined instruction.


Unplug the All-In-One from the wall outlet; wait a few seconds, then plug the All-In-One back in, and turn the power on. If the problem remains, then replace the All-In-One.

Service:


120B Address Error Firmware attempted to access invalid address space.


Unplug the All-In-One from the wall outlet; wait a few seconds, then plug the All-In-One back in, and turn the power on.

Service:


Error


2-11 Service Manual

Lexmark S800 Series

120C NVRAM Error An error was detected in reading or writing NVRAM.



Service:


120D Never Error Stack over and under flow error; Code error.



Service:


120E Software Detected Error An error condition was detected in the software control code.



Service:

Reinstall the print driver. If the problem remains, then replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21.

121A Loop Timeout Error Error detected that a while loop or similar loop timed out before the event it was waiting on finished.



Service:


121B NVRAM Control Section Corrupted

Indicates that the control section of NVRAM is corrupted.



Service:


Error



Lexmark S800 Series

121C Internal Firmware Error Firmware encountered an unexpected condition.



Service:


121D Internal Firmware Error Firmware encountered an unexpected condition.



Service:


121E Internal Firmware Error Firmware encountered an unexpected condition.



Service:


Error


2-13 Service Manual

Lexmark S800 Series

Service checks

System board service checks

Symptom Action

Dead machine Check the power supply connector J4, pin 1 for approximately 30 V dc. If voltage is incorrect, replace the power supply. If voltage is correct, check all other connectors on the system board. If connectors are okay, replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21.

• Carrier transport motor does not operate.

• Paper feed motor does not operate.

• Control panel buttons do not work.

• Power light does not come on.

• Tank access and end-of-forms sensors do not work.

• Check the carrier transport motor connector J2 on the system board. If it is connected, check for approximately 30 V dc on pins 1 and 2 or at the wire connections located on the rear of the carrier transport motor. If voltage is incorrect, replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21. If voltage is correct, then replace the frony lid. If the front lid does not correct the problem, then replace the All-In-One.

• Check the paper feed motor connector J3 on the system board. If it is connected, check for approximately 30 V dc on pins 1 and 2. If the voltage is incorrect, then replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21. Although the paper feeds turns in one direction, the paper feed motor turns in two directions. If the paper feed motor turns in one direction only, then replace the system board.

• If the control panel buttons do not work or the power light does not come on, then replace the front lid.

• If the tank access or end-of-forms sensors do not work, then replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21.

• If it is determined that the tank access or End-of-Form sensor does not function correctly, then replace the print engine.


Lexmark S800 Series

Carrier service checks

Symptom Action

• The carrier slams against the side frame.

• There is no carrier movement.

• Check the encoder strip for proper installation or contamination. Clean as possible.

• Check the carrier cable connectors on the system board. If connectors are okay, then replace the system board. See “System board with media sensor, cable, and spring removal” on page 4-21. If that does not fix the problem, then replace the print engine. See “Print engine removal” on page 4-25.

Poor print quality Be sure that the All-In-One contains good print tanks.

Be sure the print tank nozzle plate is clean. Clean with a soft cloth.

Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check for:

• Correct type of paper

• Curled or wrinkled paper

• Paper path obstructions

• Feed roller wear or looseness

• Worn gears or binds

If the paper feed roller or gears are defective, then replace the All-In-One.

Blurred print and voids can be caused by problems in the carrier transport area. Check the following:

• Carrier transport belt for wear

• Idler pulley parts for wear, damage, or looseness

• Carrier guide rod for wear or dirt. If the rod is dirty, then clean and lubricate it.

The carrier to carrier frame engagement should be lubricated with grease P/N 40X0179.

If the carrier transport belt is worn, then replace the print engine. See “Print engine removal” on page 4-25.

If the idler pulley parts are defective, then replace the print engine. See “Print engine removal” on page 4-25.

3-1 Service Manual

Lexmark S800 Series

3. Diagnostic aids

Test mode

Test page

This test prints the test page:

1. Select or the low ink icon from the main menu screen.

2. Select Print Test Page.

3. The test page prints.

Uninstall/reinstall instructions for Windows users

If you already have the Lexmark S800 Series printer driver installed and are experiencing any problems, follow these instructions to uninstall and reinstall your original driver.

For Windows 2000, Windows XP, Windows Vista, and Windows 7

1. Unplug the USB cable from the Lexmark S800 Series printer.

2. From your desktop, click Start > Programs > Lexmark > S800 Series > Uninstall Lexmark S800 Series.

3. This message appears: “This program will uninstall the Lexmark S800 Series from yoursystem. Do you wish to

continue?” Click Yes.

4. Wait several minutes while the uninstall program uninstalls your Lexmark S800 Series printer.

5. When prompted to restart the computer, click Continue with the reboot of the computer now.

6. Insert the Lexmark S800 Series CD.

7. From the Install Software screen, click Install and follow the instructions on the screen.

Note: Do NOT reconnect the USB cable until instructed by the install software.

Uninstall/reinstall instructions for Mac users


1. Close all open software applications.

2. From the Dock, double-click the Lexmark S800 Series folder. If the folder is not in the Dock, navigate to Finder >

Applications, and double-click on the Lexmark S800 Series folder.

3. Double-click the Uninstaller icon.

4. Follow the instructions on the computer screen to uninstall your Lexmark S800 Series driver.

5. Restart the computer before reinstalling the Lexmark S800 Series driver.

6. Insert the Lexmark S800 Series CD.

7. Click Install to launch the installer.

8. Follow the instructions on the computer screen to reinstall the driver.

Note: Do NOT reconnect the USB cable until instructed by the install software.

Diagnostic aids 3-2

Lexmark S800 Series

Uninstall/reinstall instructions for Linux users


Uninstallation for DEB-based package:

1. Log in as root.

2. Uninstall the DEB package: dpkg -r <package>

Example:

a. For installed driver with JRE

#dpkg -r lexmark-inkjet-driver-wjre#dpkg -r lexmark-wsu

b. For installed driver without JRE

#dpkg -r lexmark-inkjet-driver

#dpkg -r lexmarl-wsu

Uninstallation for RPM-based package

1. Log in as root.

2. Uninstall the RPM package: rpm -e <package>

Example:

a. For installed driver with JRE

#dpkg -e lexmark-inkjet-driver-wjre

#dpkg -e lexmark-wsu

b. For installed driver without JRE

#dpkg -e lexmark-inkjet-driver#dpkg -e lexmark-wsu

Installation instructions

1. Do not attach the printer via USB to the Linux machine.

2. Exract the zip file.

For DEB-based systems

a. For 32-bit operating system

Driver bundled without JRE: lexmark-inkjet-driver-2.0-1.i386.deb.sh. tar.gz

Driver bundled with JRE: lexmark-inkjet-driver-wJRE-2.0-1.i386.deb.sh. tar.gz

b. For 64-bit operating system

Driver bundled without JRE: lexmark-inkjet-driver-2.0-1.am64.deb.sh.tar.gzDriver bundled with JRE: lexmark-inkjet-driver-wJRE-2.0-1.am64.deb.sh.tar.gz

For RPM-based systemsa. For 32-bit operating system

Driver bundled without JRE: lexmark-inkjet-driver-2.0-1.i386.rpm.sh.tar.gz

Driver bundled with JRE: lexmark-inkjet-driver-wJRE-2.0-1.i386.rpm.sh.tar.gz

b. For 64-bit operating system

Driver bundled without JRE: lexmark-inkjet-driver-2.0-1.x86_64.rpm.sh.tar.gz

Driver bundled with JRE: lexmark-inkjet-driver-wJRE-2.0-1.x86_64.rpm.sh.tar.gz

3. Run the installer script file by doble-clicking on the icon, and click the Run in Terminal button; or run the script via

the the command line.

4. Follow the instructions on the screen.

Note: Do not reconnect the USB cable until instructed by the install software.

4-1 Service Manual

Lexmark S800 Series

4. Repair information

This chapter explains how to make adjustments to the All-In-One and how to remove defective parts.

Warning: Read the following before handling electronic parts.

Handling ESD-sensitive parts

Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage

to ESD-sensitive parts, follow the instructions below:

• Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until you are ready to install

the part into the machine.

• Make as few movements as possible with your body to prevent an increase of static electricity from clothing

fibers, carpets, and furniture.

• Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges any

static electricity in your body to the machine.

• Hold the ESD-sensitive part by its edge connector shroud (cover); do not touch its pins. If you are removing a

pluggable module, use the correct tool.

• Do not place the ESD-sensitive part on the machine cover or on a metal table; if you need to put down the ESD-

sensitive part for any reason, first put it into its special bag.

• Machine covers and metal tables are electrical grounds. They increase the risk of damage, because they make

a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths

without being grounded.)

• Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install machine covers when

you are not working on the machine, and do not put unprotected ESD-sensitive parts on a table.

• If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case).

• Be extra careful in working with ESD-sensitive parts when cold-weather heating is used, because low humidity

increases static electricity.

Repair information 4-2

Lexmark S800 Series

Removal procedures

The following procedures are arranged according to the name of the All-In-One part discussed.

General precautions

Use caution when disassembling and reassembling components. The close proximity of cables to moving parts makes

proper routing a must. When components are removed or replaced, any cables disturbed must be replaced as closely

as possible to their original positions. Before removing any component from the machine, be sure you note the cable

routing.

When servicing the machine:

• Verify that documents are not stored in memory.

• Move the print cartridge to the far right to cap the nozzles.

• Always remove the power cord from the AC wall outlet. Do not RE-BRICK the printer.

• Use a flat and clean surface.

• Use only authorized replacement parts.

• Do not force plastic parts.

CAUTION:

Unplug the power cord before removing any parts.

4-3 Service Manual

Lexmark S800 Series

Duplex and rear fax/phone cables cover removal

1. Remove the paper tray.

2. Press down on the button (A) to remove the duplex.


Lexmark S800 Series

3. Press down on the rear fax/phone cables cover (B) to unlatch it from the rear of the printer.

4. Remove the rear fax/phone cables cover.

4-5 Service Manual

Lexmark S800 Series

Right side cover removal

1. Place the printer on its left side.

Note: Be sure to protect the printer from marring.

2. Remove the four screws (A).

3. Unsnap the right side cover, lift and remove.


Lexmark S800 Series

Left side cover removal

1. Place the printer on its right side.


2. Press in on the power supply cover (A), and slide up to remove.

3. Press in on the red button (B) to remove the power supply.

4-7 Service Manual

Lexmark S800 Series

4. Remove the four screws (C).

5. Unsnap the left side cover, lift and remove.


Lexmark S800 Series

Inner front cover removal

1. Remove the right side cover. See “Right side cover removal” on page 4-5.

2. Remove the left side cover. See “Left side cover removal” on page 4-6.

3. Remove the four screws (A).

4. Remove the inner front cover.

4-9 Service Manual

Lexmark S800 Series

Lower front door removal


2. Remove the leftside cover. See “Left side cover removal” on page 4-6.

3. Remove the inner front cover. See “Lower front door removal” on page 4-9.

4. Place the printer on its right side.

Note: Be careful not to mar the finish of the printer.

5. Gently open the front door.

6. Align the top hinge pivot (A) with the opening in its socket.


Lexmark S800 Series

7. Lift the metal link (B) from its attachment to the hinge while pulling the hinge from its socket.

4-11 Service Manual

Lexmark S800 Series

8. Rotate the top of the door away from the printer, and lift the door away from its bottom hinge (C).

9. Remove the lower front door.


Lexmark S800 Series

Rear cover removal



3. Disconnect the rear cover from the right side of the printer.

4. Disconnect the rear cover from the left side of the printer.

5. Lift the rear cover away from the printer, and remove.

4-13 Service Manual

Lexmark S800 Series

Front door/operator panel/camera assembly removal



3. Remove the inner front cover. See “Inner front cover removal” on page 4-8.

4. Remove the lower front door. See “Lower front door removal” on page 4-9.

5. Remove the rear cover. See “Rear cover removal” on page 4-12.

6. Tilt the top of the printer forward, and disconnect the two mini USB cables (A) from the right side of the system

board.

CAUTION: Hold or tape the assembly lid shut to prevent it from falling open.

7. Disconnect the APPSFFC cable (B) and the LID Sens cables (C) from the system board.


Lexmark S800 Series

8. Using a metal hook, disconnect the USB cable (D) from the system board.

9. Disconnect the front door/operator panel/camera assembly from its right side hinge (E).

4-15 Service Manual

Lexmark S800 Series

10. Disconnect the front door/operator panel/camera assembly from its left side hinge (F).

11. Lift the door/operator panel/camera assembly, and remove.


Lexmark S800 Series

Camera assembly with front door and operator panel removal

1. Remove the front door/operator panel/camera assembly. See “Front door/operator panel/camera assembly

removal” on page 4-13.

2. Place the camera assembly with front door and operator panel on its face.


3. Disconnect and remove the right side spring (A) and the left side spring (B).

4. Turn the camera assembly upright, and open the front cover.

4-17 Service Manual

Lexmark S800 Series

5. Place a spring hook behind the right hinge between the camera lid and tube (C), and gently pull the tube past

the latch to disconnect the camera assembly. Repeat to disconnect the left side.

6. Remove the flat ribbon cable thought the opening of the top cover.

7. Without cutting the wire tie, unloop the black cable from the torroid, and pull through the opening of the top

cover.

Note: If then torroid needs to be removed, then be sure to reinstall it.

8. Lift the camera assembly with the front door and operator panel, and remove.


Lexmark S800 Series

USB connector and cable removal

1. Remove the rear cover.

2. Remove the two screws (A)., and disconnect the cable (B).

3. Lift and remove the USB connector and cable.

4-19 Service Manual

Lexmark S800 Series

Fax card removal


2. Remove the left side cover. “Left side cover removal” on page 4-6.

3. Remove the rear cover. “Rear cover removal” on page 4-12.

4. Disconnect the two ribbon cables (A), and remove the two screws (B).

5. Lift the fax card cover, and remove the fax card.


Lexmark S800 Series

Exit tray assembly removal



3. Remove the one screw (A).

4. Lift and remove the exit tray assembly.

4-21 Service Manual

Lexmark S800 Series

System board with media sensor, cable, and spring removal






5. Disconnect all cables from the system board.

6. Remove the four screws (A) from the system board shield, and the one screw (B) from the system board.

7. Lift the system board, and remove.

8. Remove the media sensor.


Lexmark S800 Series

Star wheel cross bar assembly removal

Note:

• It is not necessary to remove the printhead, but doing so will give better visibility for installation.

• The carrier has to be unlocked so that it can be moved to access the starwheel screws.






5. Open the inner front door.

6. Slide the printhead to the right, and remove the left side screw (A) using a Phillips screwdriver. Repeat for the

right side screw.

7. Lift the starwheel crossbar, and remove.

4-23 Service Manual

Lexmark S800 Series

Bottom power supply cover removal

1. Place the machine on its right side.

2. Push out on the cover with the thumb until it unsnaps.

3. Slide the bottom LVPS cover out, and remove.


Lexmark S800 Series

Wireless (INA) card removal



3. Remove the inner front cover. See “Inner front cover removal” on page 4-8.

4. Remove the two screws from the metal RFID card bracket, and pull out slightly.

5. Remove the one screw (A), and remove the top of the wireless card cover.

6. Disconnect the mini USB cable (B) from the wireless card.

7. Remove the one screw from the top of the wireless card.

8. Lift the wireless card out, and remove.

Installation note: To install the wireless (INA) card, place the card back in its cover, connect the cable, place the top

cover back on the housing, and place the housing back in the printer.

4-25 Service Manual

Lexmark S800 Series

Print engine removal






The print engine is what remains.

Locations and connectors 5-1

Lexmark S800 Series

5. Locations and connectors

Locations

Front view

Number Part Function

1 Scanner lid Allows access to the scanner glass

2 Scanner glass Scans, copies, or faxes photos and documents

3 Scanner clip Holds photos, cards, or other small media in place

4 Placement corner Correctly places photos and documents on the scanner glass

5 Printer operator panel with touch screen

Operates the printer

6 Paper support Loads paper and accesses paper jams

7 Paper guide adjustment lever Adjusts the paper guides

8 PictBridge and USB pot Connects a PictBridge-enabled digital camera or a flash drive to the printer

9 Memory card slot Inserts a memory card

10 Front door Accesses the ink cartridges

11 Paper exit tray Holds paper as it exits the printer

5-2 Service Manual

Lexmark S800 Series

Rear/inside views


1 Customer support label Identifies the model number of the printer, the customer support hot line, the ink tank information, and the MAC address

2 Front door Accesses the ink cartridges

3 Printhead access door Access the printhead and paper jams

4 Cloth storage pocket Stores the touch screen cloth

5 Ink cartridge access Allows to install, replace, or remove ink cartridges

6 Paper support Loads paper and accesses paper jams

7 LINE port Connects the printer to an active telephone line through a standard wall jack (RJ-11), DSL filter, VolP adapter, or any other adapter that allows access the phone line to send and receives faxes.

8 EXT port Connects additional devices (telephone or answering machine) to the printer and the telephone line

9 Power supply with port Connects the printer to a power source using the power cord

10 Fax cover Protects the fax area

11 Duplex unit Provides for printing on both sides of a sheet of paper

12 Duplex button Releases duplex to allow access to paper jams

13 USB port Connects the printer to a computer using a USB cable

Warning: Do not touch the USB port except when plugging in or removing a USB cable or installation cable.


Lexmark S800 Series

Base view


1 Power supply with port Connects the printer to or disconnects the printer from a power source

2 Power supply cover Protects the power supply

5-4 Service Manual

Lexmark S800 Series

System board


Lexmark S800 Series

System board connections

Connector Description

J1 Paper pick motor

J2 Transport carrier motor

J3 Paper feed motor

J4 Power supply

J6 Maintenance motor

J9 Not used

J11 Not used

J12 INA card

J13 Operator panel

J15 Fax card

J16 USB (from host)

J18 Cardreader

J19 Touch screen

J20 PictBridge

J21 Carrier

J22 Carrier

J23 Carrier

J25 Paper feed encoder sensor

J26 EOF sensor

J27 Front lower cover sensor

J28 Pick encoder

J30 Stage sensor

J31 RFID card

J34 DSP (digital signal processor)

J35 Maintenance sensor

PS1 Ink tank access sensor

6-1 Service Manual

Lexmark S800 Series

6. Preventive maintenance

This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help prevent

problems and maintain optimum performance.

Lubrication specifications

Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use grease to lubricate the following:

• All gear mounting studs

• The left and right ends of the large feed roller at the side frames

• The carrier to carrier frame engagement

• The carrier guide rod, and carrier guide rod bearings

Warning: Keep grease from coming into contact with any electrical components, as this may cause printer damage or

failure. Do not lubricate the scanner rod or bearing after replacing.

Parts catalog 7-1

Lexmark S800 Series

7. Parts catalog

How to use this parts catalog

The following legend is used in the parts catalog:

• Asm-index: Identifies the assembly and the item in the diagram. For example, 2-1 indicates assembly 2 and

item number 1.

• Units/mach: Refers to the number of units actually used in the machine or product.

• Units/FRU: Refers to the number of units packaged together and identified by the part number.

• NS: (Not shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the

illustration.

• PP: (Parts Packet) in the parts description column indicates that the part is contained in a parts packet.

Asm-

Index

Units/

mach

Units/

FRUDescription

7-2 Service Manual

Lexmark S800 Series

Assembly 1: Covers

Parts catalog 7-3

Lexmark S800 Series

Assembly 1: Covers*

Asm- Index Part number Units/mach Units/ FRU Description

1-1 3062194 Media input tray

2 3062152 Rear cover

3 DOP0072 Right side cover (black)

3 DOP0071 Right side cover (silver)

4 DOP0081 Print engine (includes system board, fax card, RFID card, XT)

4 DOP0074 Print engine (excludes system board, fax card, RFID card, XT)

5 DOP0076 Inner lower front door assembly

6 3062154 Lower front cover

7 DOP0075 Power supply bottom cover (black)

7 3062162 Power supply bottom cover (silver)

8 DOP0073 Left side cover (black)

8 3062154 Left side cover (silver)

9 21D0932 Universal power supply

10 DOP0066 Paper output tray (black, not included with print engine))

10 3062172 Paper output tray (silver, not included with print engine)

11 DOP0069 Scanner lid with operator panel (not included with print engine)

12 DOP0078 Camera assembly (not included with print engine)

12 DOP0085 Camera and front door assembly (not included with print engine)

13 3062153 Rear fax cables cover

NS 3061264 Duplex unit

*Part numbers are for internal use only. They cannot be ordered from Lexmark.

7-4 Service Manual

Lexmark S800 Series

Assembly 2: Electronics

Parts catalog 7-5

Lexmark S800 Series

Assembly 2: Electronics*

Asm- Index Part number Units/machUnits/

FRUDescription

2-1 DOP0070 Controller PCBA

2 DOP0077 Media sensor (Skystar)

3 3062128 Wireless card, Hsng and cable

4 3062395 RFID with bracket

5 3062367 Encoder strip

6 3061226 Main controller board

7 3061883 Fax card

NS 3062260 Star wheel cross bar assembly

NS 3062142 USB connector with cable

*Part numbers are for internal use only. They cannot be ordered from Lexmark.

Index I-1

Lexmark S800 Series

Index

AAcronyms 1-11

DDiagnostic aids 3-1

Test mode 3-1Uninstall/reinstall instructions for Linux users 3-2Uninstall/reinstall instructions for Mac users 3-1Uninstall/reinstall instructions for Windows users 3-1

Diagnostic information 2-1Power-On Self Test (POST) sequence 2-1Service checks 2-13

Carrier 2-14System board 2-13

Theory of operation 2-1Paper path 2-2

Troubleshooting tables 2-3Error code table 2-4

GGeneral information 1-1

Copy specifications 1-5Media specifications 1-6Print specifications 1-2Understanding the operator panel 1-9

LLocations and connectors 5-1

Base view 5-3Front view 5-1Rear view 5-2System board 5-4

System board connections 5-5

MMaintenance approach 1-11

PParts catalog

Covers 7-2Part numbers

21D0932 Universal power supply 7-33061264 Duplex unit 7-33062152 Rear cover 7-33062153 Rear fax cables cover 7-33062154 Left side cover (silver) 7-33062154 Lower front cover 7-33062162 Power supply bottom cover (silver)

7-33062172 Paper output tray (silver) 7-33062194 Media input tray 7-3DOP0066 Paper output tray (black) 7-3DOP0069 Scanner lid with operator panel 7-3DOP0071 Right side cover (silver) 7-3DOP0072 Right side cover (black) 7-3DOP0073 Left side cover (black) 7-3

DOP0074 Print engine (excludes system

board, fax card, RFID card, XT) 7-3DOP0075 Power supply bottom cover (black)

7-3DOP0076 Inner lower front door assembly

7-3DOP0078 Camera assembly 7-3DOP0081 Print engine (includes system

board, fax card, RFID card, XT) 7-3DOP0085 Camera and front door assembly

7-3Electronics 7-4

Part numbers

3061226 Main controller board 7-53061883 Fax card 7-53062128 Wireless card, Hsng and cable 7-53062142 USB connector with cable 7-53062260 Star wheel cross bar assembly 7-53062367 Encoder strip 7-53062395 RFID with bracket 7-5DOP0070 Controller PCBA 7-5DOP0077 Media sensor (Skystar) 7-5

How to use 7-1Preventive maintenance 6-1

Lubrication specifications 6-1

RRepair information 4-1

Removal procedures 4-2Bottom power supply cover removal 4-23Camera assembly with front door and operator pan-

el removal 4-16Duplex and rear fax/phone cables cover removal

4-3Exit tray assembly removal 4-20Fax card removal 4-19Front door/operator panel/camera assembly remov-

al 4-13Inner front cover removal 4-8Left side cover removal 4-6Lower front door removal 4-9Print engine removal 4-25Rear cover removal 4-12Right side cover removal 4-5Starwheel cross bar removal 4-22System board with media sensor, cable, and spring

removal 4-21USB connector and cable removal 4-18Wireless (INA) card removal 4-24

SSafety information v

TTools required 1-11

Documents

Service Manual - Lexmarksupport.lexmark.com/resources/sites/LEXMARK/content/live/SERVICE... · Service Manual Lexmark S800 Series ... Uninstall/reinstall instructions for Mac users