Lexmark 4023 Service manual

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Page 1

Lexmark Optra TM W810

Laser Printer

• Table of Contents

•Start Diagnostics

• Safety and Notices

4023-001

• Trademarks

•Index

• Manuals Menu

Lexmark and Lexmark with diamond design are trade ma rks of Lexmark International, Inc., registered in the United States and/or ot her countries.

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4023-001

Edition: March 24, 2006 The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMARK INTERN ATIONAL, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING , BUT NOT LIMITED TO, THE IMPLIED W A RRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not all o w di sc la im er o f e xp res s o r im plie d w ar r ant i es in ce rta in t r ansa ct io ns , t he refore, t hi s statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the 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.

A form for reader’s comments is provided at the back of this publication. If the form has been removed, comments may be addressed t o Lexmark International, Inc., Department D22/032-2, 740 West New Circle Road, Lexington, Kentucky 4055 0, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

Lexmark, MarkNet, MarkVision, Optra and OptraImage are trademarks of Lexmark International, Inc., registered in the United Sta tes and/or other co untries .

Other tradema rks are the property of their respective owner s.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Right s in Technical Data and Computer Software clause at DFARS 25 2.227-7013 and in applicable FAR provisions: Le x mark International, Inc., Lexington, KY 40550.

U.S.A. P/N: 12G3978

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Notices and Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Printer (Main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Printer/Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

General Description of Each Section . . . . . . . . . . . . . . . . . . . . . . . . . .9

Paper Feed Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Printhead Unit (Exposure Section). . . . . . . . . . . . . . . . . . . . . . . . . .9

Imaging Cartridge (Charging, Development Section) . . . . . . . . . . .9

Image Transfer Section (Release Section) . . . . . . . . . . . . . . . . . . .9

Fusing Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Cleaning Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Paper Exit Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

General Flow for Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Paper Feed Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Taking Up Paper–Tray 1 (1st Paper Cassette) . . . . . . . . . . . . . . . 11

Tray 1 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1st Cassette Tray 1 Paper Size Detection. . . . . . . . . . . . . . . . . . .15

Tray 2 (2nd Paper Cassette) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Taking up Paper–Tray 2 (2nd Paper Cassette) . . . . . . . . . . . . . . .16

Tray 2 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Edge Guide and Trailing Edge Stop. . . . . . . . . . . . . . . . . . . . . . . .20

Paper Lifting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Cassette-in-Position Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Paper Near Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Paper Separating Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Paper Take-Up Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Printhead Unit (Exposure section) . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Imaging Cartridge (Charging/Development Section) . . . . . . . . . . . . .28

Development Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

iii

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Toner Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Image Transfer Section (Release Section) . . . . . . . . . . . . . . . . . . . . 34

Optical Erase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Fusing Sectio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Temperature Control Using The Thermistor . . . . . . . . . . . . . . . . . 36

Thermostat (TS1) and Heater Lamp Fuse (TF1). . . . . . . . . . . . . . 36

Fusing Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Fus ing PPM Cont rol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Paper Exit Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Paper Path Through Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Detection of a New Imaging Cartridge . . . . . . . . . . . . . . . . . . . . . . . . 39

Right Door Interlock Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Duplex Unit Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Switchback Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Transport and Duplex Paper Take-Up Mechanism . . . . . . . . . . . . 43

Paper Deck 2500-Sheet (LCC) Option . . . . . . . . . . . . . . . . . . . . . . . 45

Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Vertical Transport Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . 45

Paper Take-Up Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Paper Take-Up Retry Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Paper Separating Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Paper Pressure Releasing Mechanism. . . . . . . . . . . . . . . . . . . . . 53

Paper Take-Up Roll Retracting Mechanism . . . . . . . . . . . . . . . . . 54

Edge Guides and Trailing Edge Stop . . . . . . . . . . . . . . . . . . . . . . 54

Paper Size Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

LCC-in-Position Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Paper Near Empty Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Paper Dehumidifying Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Mailbox/Transport Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Paper Transport Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Paper Entrance Switching Mechanism . . . . . . . . . . . . . . . . . . . . . 64

Paper Transport Mechanism (Horizontal Transport Unit) . . . . . . . 64

Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Paper Full Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Paper Output Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Finisher Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

iv Service Manual

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Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Paper Transport Path Switching Mechanism. . . . . . . . . . . . . . . . .69

Paper Transport Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Punch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Finisher Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

CD Aligning Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Shifting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Finisher Tray Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Paper Holding Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Elevator Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Stapling Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Horizontal Transport Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Service Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Operator Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Print Quality Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Paper Feed Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Other Printer Malfunction Symptom Table. . . . . . . . . . . . . . . . . . .31

LCC 2500-Sheet Tray 4 Symptom Table. . . . . . . . . . . . . . . . . . . .32

Mailbox Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Finisher Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Printer Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

No Power Service Check (923) . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Fuser (Abnormal Temperature) Service Check (923) . . . . . . . . . .34

Fuser (Temperature Low) Service Check (920/922) . . . . . . . . . . .35

Toner Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Print Quality Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Black Page Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

White Spots Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Toner Smudges On Backside Service Check . . . . . . . . . . . . . . . .37

Low Image Density Service Check . . . . . . . . . . . . . . . . . . . . . . . .38

Foggy Background Service Check. . . . . . . . . . . . . . . . . . . . . . . . .39

White/Black Lines Service Check . . . . . . . . . . . . . . . . . . . . . . . . .40

Offset Image Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Blank Print Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Image Space Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Paper Feed Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Paper Feed Pickup Tray 1 (250-Sheet) Service Check . . . . . . . .44

Paper Feed Pickup Tray 2&3 (500-Sheet) Service Check . . . . . . 44

Paper Feed Synchronizing Roll/Registration Service Check . . . .45

Paper Feed Fuser/Exit Service Check . . . . . . . . . . . . . . . . . . . . .46

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4023-001

Paper Feed In Duplex Service Check . . . . . . . . . . . . . . . . . . . . . 46

Paper Feed In Horizontal Transport Service Check . . . . . . . . . . . 48

Paper Feed Mailbox Service Check . . . . . . . . . . . . . . . . . . . . . . . 48

Paper Feed Finisher Service Check . . . . . . . . . . . . . . . . . . . . . . . 50

Paper Feed LCC (2500-Sheet Tray 4) Service Check . . . . . . . . . 51

Paper Feed Hole Punch Service Check . . . . . . . . . . . . . . . . . . . . 52

Finisher Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Finisher Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Finisher Elevator Tray Service Check (993) . . . . . . . . . . . . . . . . . 53

Finisher Tray Drive Service Check (994) . . . . . . . . . . . . . . . . . . . 54

Finisher Shift Plate Drive Service Check (995) . . . . . . . . . . . . . . . 54

Finisher Paper Aligning Service Check (996) . . . . . . . . . . . . . . . . 54

Finisher Stapler Drive Service Check (997) . . . . . . . . . . . . . . . . . 56

Finisher Paper Holding Tray Drive Service Check (998). . . . . . . . 56

Finisher Upper Entrance Service Check . . . . . . . . . . . . . . . . . . . . 57

Mailbox Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Mailbox Power Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Mailbox Bin 1–10 Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . 59

Mailbox Transport Drive Service Check (935). . . . . . . . . . . . . . . . 59

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Operator Menu Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Diagnostics Mode Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . 1

Printing Menu Settings Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Quick Test Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Diagnostics–Print Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Hardware Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Output Bin Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Finisher Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Base Printer Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Disk Test/Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Mailbox Internal Diagnostic Test. . . . . . . . . . . . . . . . . . . . . . . . . . 26

Repa ir Informatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Disassembly and Cleaning Precautions . . . . . . . . . . . . . . . . . . . . . 1

vi Service Manual

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4023-001

Handling the Printed Circuit Boards with MOS ICs . . . . . . . . . . . . .1

Image Cartridge/PC (I/C) Handling Precautions . . . . . . . . . . . . . . .2

Parts Not To Be Touched. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Printer (Main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Mailbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Resetting Maintenance Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Resetting Hole Punch Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Resetting Fuser Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Resetting Transfer Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Printer Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Pre-disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Outer Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

1st Cassette/250-Sheet (Tray1) Paper Take-Up Roller Removal .16

250-Sheet Cassette (Tray 1) Paper Take-Up Rolls Removal . . . .16

250-Sheet Cassette (Tray 1) Paper Take-Up Rolls Cleaning . . . .17

500-Sheet Cassette (Tray 2 and 3) Vertical Transport Roller/Rolls

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

500-Sheet Cassette (Tray 2 and 3) Paper Lifting Springs Replace-

ment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

500-Sheet Cassette (Tray 2 and 3) Paper Size Detecting Board

(PWB-S2) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Image Transfer Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . .21

Image Cartridge/PC (I/C) Thermistor (TH2) Removal . . . . . . . . . .22

Image Transfer Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Synchronizing Roller Sensor (PC2) Removal . . . . . . . . . . . . . . . .23

Pre-transfer Guide Plate Register Plate (PWB-R2) Removal . . . .24

Synchronizing Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Cooling Fan Motor (M3) and I/C Filter Removal . . . . . . . . . . . . . .26

Fusing Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Paper Exit Sensor (PC3) and Actuator Removal . . . . . . . . . . . . . .27

Heater Lamp Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Heater Lamp (H1) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Fusing Roller Thermistor (TH1) Removal . . . . . . . . . . . . . . . . . . .29

Fusing Roller Thermostat (TS1) Removal . . . . . . . . . . . . . . . . . . .30

Paper Exit Full Sensor (PC12) Removal . . . . . . . . . . . . . . . . . . . .31

Eraser Duct Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . .32

Erase Lamp (LA1) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Fuser Frame Resistor Board (PWB-R1) Removal . . . . . . . . . . . . .34

1st Ca ssette Paper Em pty Sensor (PC4) Removal. . . . . . . . . . . .35

Image Cartridge/PC (I/C) Cooling Fan Motor (M9) Removal. . . . . 36

High Voltage Unit (HV1) Removal . . . . . . . . . . . . . . . . . . . . . . . . .37

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Printer Main Engine Board (PWB-A) Removal . . . . . . . . . . . . . . . 38

Printhead Unit Assembly (PH) Removal . . . . . . . . . . . . . . . . . . . . 40

Right Door Switch (S3) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 43

Power Supply Unit (PU1) Removal . . . . . . . . . . . . . . . . . . . . . . . . 44

CPM (Power Supply Safety) Switch and PWB-L Removal . . . . . . 45

Power Unit Cooling Fan Motor (M4) Removal. . . . . . . . . . . . . . . . 46

Ozone Fan Motor (M8) and Ozone Filter Removal . . . . . . . . . . . . 47

1st Paper Cassette (Tray 1) Paper Size Detecting Board Removal .

Bottle Cover Sensor (PC10) Removal. . . . . . . . . . . . . . . . . . . . . . 49

Agitating Motor (M10) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Main Hopper Motor (M6) and Sub Hopper Motor (M7) Removal . 51

Transport Motor (M2) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Image Cartridge/PC (I/C) Drive Motor (M1) Removal . . . . . . . . . . 53

Right Door Interlock Switch (S2) Removal . . . . . . . . . . . . . . . . . . 54

Toner Detecting Read Switch (S4) Removal. . . . . . . . . . . . . . . . . 55

1st Cassette (Tray 1) Paper Near Empty Sensor (PC5) Removal 57

1st Cassette (Tray 1) Set Sensor (PC6) Removal . . . . . . . . . . . . 58

1st Cassette (Tray 1) Paper Take-Up Solenoid (SL1) Removal . . 59

Double Feed Detection Sensor Board (PWB-H) Removal . . . . . . 60

500-Sheet Cassette (Tray 2 and 3) Control Board (PWB-A2) Remov-

al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

500-Sheet Cassette (Tray 2 and 3) Paper Take-Up Roller Removal

500-Sheet Cassette (Tray 2 and 3) Paper Empty Sensor (PC22) Re-

moval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

500-Sheet Cassette (Tray 2 and 3) Paper Near Empty Sensor (PC25)

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

500-Sheet Cassette (Tray 2 and 3) Right Door Detecting Sensor

(PC23) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

500-Sheet Cassette (Tray 2 and 3) Paper Take-Up Solenoid (SL2)

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Duplex Unit Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Duplex Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Duplex Unit Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Paper Deck 2500-Sheet Tray 4 (LCC) Removal Procedures . . . . . . 70

Exterior Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Paper Take-Up Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Paper Take-Up Rolls Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Feed Roll, Separator Roll and Torque Limiter Assembly Removal 79

Paper Take-Up Roll Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Feed Roll and Separator Roll Cleaning. . . . . . . . . . . . . . . . . . . . . 80

Vertical Transport Roller/Rolls Cleaning . . . . . . . . . . . . . . . . . . . . 81

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Roll with a Torque Limiter Cleaning. . . . . . . . . . . . . . . . . . . . . . . .81

Finisher Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

External Covers Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Punch Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Stapler Unit Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Rear Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Front Cable Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Front Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Mailbox Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Storage Unit Cover Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Horizontal Transport Unit Cover Removal . . . . . . . . . . . . . . . . . . .92

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Printer with Opti o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Printer Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Electrical Components (cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Printer Main Engine Board PWB-A . . . . . . . . . . . . . . . . . . . . . . . . .8

RIP Controller Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

High Voltage Board (HV1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Power Unit (PU1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Network Interface Card (NIC). . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Paper Cassettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Fixed Paper Size Cassette (Tray 1 only) . . . . . . . . . . . . . . . . . . . .12

Universal Cassette (Tray 2,3 and 500-Sheet Option) . . . . . . . . . .12

Cross-Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Paper Cassette Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Paper Cassette Electrical Components . . . . . . . . . . . . . . . . . . . . .14

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Duplex Cross-Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Duplex Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Duplex Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Paper Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Paper Deck Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . .19

Paper Deck Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Paper Deck Electrical Components . . . . . . . . . . . . . . . . . . . . . . . .21

Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Finisher Cross-Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Finisher Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Finisher Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . .26

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Finisher Main Board PWB-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

External View (Front: When Connected To Printer) . . . . . . . . . . . 29

External View (Rear: When Connected To Printer) . . . . . . . . . . . . 29

Mailbox External View (Each Section) . . . . . . . . . . . . . . . . . . . . . 30

Mailbox Horizontal Transport Unit: Cross-Sectional View. . . . . . . 30

Mailbox Horizontal Transport Unit: Electrical Components. . . . . . 31

Mailbox Horizontal Transport Unit: Mechanical Components . . . . 31

Mailbox Storage Unit: Cross-Sectional View. . . . . . . . . . . . . . . . . 32

Mailbox Storage Unit: Electrical Components. . . . . . . . . . . . . . . . 33

Mailbox Storage Unit: Mechanical Components . . . . . . . . . . . . . . 34

Mailbox Storage Unit: Main Board PWB-A . . . . . . . . . . . . . . . . . . 34

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Assembly 1: Printer Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Assembly 2: Printer Frames (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Assembly 3: Printer Frames (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Assembly 4: Printer Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Assembly 5: Printer Fuser (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Assembly 6: Printer Fuser (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Assembly 7: Printer Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Assembly 8: Printer Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Assembly 9: Printer Electrical Components . . . . . . . . . . . . . . . . . . . . 26

Assembly 10: Printer Paper Take-up . . . . . . . . . . . . . . . . . . . . . . . . . 28

Assembly 11: Printer Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Assembly 12: Printer Paper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Assembly 13: 500 Sheet Unit Housing. . . . . . . . . . . . . . . . . . . . . . . . 38

Assembly 14: 500 Sheet Unit Paper Take-up . . . . . . . . . . . . . . . . . . 42

Assembly 15: 500 Sheet Unit Paper Tray Unit (A). . . . . . . . . . . . . . . 46

Assembly 16: 500 Sheet Unit Paper Tray Unit (B). . . . . . . . . . . . . . . 48

Assembly 17: Printer Controller Card. . . . . . . . . . . . . . . . . . . . . . . . . 50

Assembly 18: Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Assembly 19: Paper Deck Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Assembly 20: Paper Deck Paper Take-up (A) . . . . . . . . . . . . . . . . . . 58

Assembly 21: Paper Deck Paper Take-up (B) . . . . . . . . . . . . . . . . . . 62

Assembly 22: Paper Deck Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Assembly 23: Paper Deck Paper Tray (A) . . . . . . . . . . . . . . . . . . . . . 70

Assembly 24: Paper Deck Paper Tray (B) . . . . . . . . . . . . . . . . . . . . . 72

Assembly 25: Finisher Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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Assembly 26: Finisher Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Assembly 27: Finisher Paper Transport (A) . . . . . . . . . . . . . . . . . . . .80

Assembly 28: Finisher Paper Transport (B) . . . . . . . . . . . . . . . . . . . .82

Assembly 29: Finisher Paper Aligning. . . . . . . . . . . . . . . . . . . . . . . . .86

Assembly 30: Finisher Assistance Tray . . . . . . . . . . . . . . . . . . . . . . .92

Assembly 31: Finisher Elevator Tray. . . . . . . . . . . . . . . . . . . . . . . . . .96

Asse m bly 32: F i nisher Punch U nit . . . . . . . . . . . . . . . . . . . . . . . . . .100

Assembly 33: Finisher Stapler Unit/Finisher Tray. . . . . . . . . . . . . . .1 02

Assembly 34: Finisher/Mailbox Horizontal Transfer (A) . . . . . . . . . .106

Assembly 35: Finisher/Mailbox Horizontal Transfer (B) . . . . . . . . . .108

Assembly 36: Mailbox Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Assembly 37: Mailbox Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 14

Assembly 38: Mailbox Paper Transport (A). . . . . . . . . . . . . . . . . . . .118

Assembly 39: Mailbox Paper Transport (B). . . . . . . . . . . . . . . . . . . .122

Assembly 40: Mailbox Paper Transport (C) . . . . . . . . . . . . . . . . . . .124

Assembly 41: Mailbox Paper Transport (D) . . . . . . . . . . . . . . . . . . .126

Assembly 42: Mailbox Paper Transport (E). . . . . . . . . . . . . . . . . . . .128

Assembly 43: Mailbox Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

Assembly 44: Optional Features (No illustration) . . . . . . . . . . . . . . .132

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

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xii Service Manual

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Notices and Safety Information

Laser No tices

The following laser notice labels may be affixed to this printer as shown:

Notices and Safety Information xiii

Page 14

4023-001

Laser Not ice

The printer is certified in the U.S. to conform to the requirements of

DHHS 21 CFR Subchapter J for Class I (1) laser products, and

elsewhere is certified as a Class I laser product conforming to the

requirements of IEC 60825.

Class I laser products are not considered to be hazardous. The

printer contains internally a Class IIIb (3b) laser that is nominally a 5

milliwatt gallium arsenide laser operating in the wavelength region of

770-795 nanometers. The laser system and printer are designed so

there is never any human access to laser radiation above a Class I

level during normal operation, user maintenance, or prescribed

service condition.

Laser

Avis relatif à l’utilisation de laser

German

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die

Anforderungen der Bestimmung DHHS (Department of Health and

Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1).

In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I,

der die Anforderungen der IEC (International Electrotechnical

Commission) 60825 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des

Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es

sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen

der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der

Drucker sind so konzipiert, daß im Normalbetrieb , bei der Wartung

durch den Benutzer oder bei ordnungsgemäßer Wartung durch den

Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde,

Menschen keinesfalls erreicht.

French

Pour les Etats-Unis : cette impri man te est certifiée conforme aux

provisions DHHS 21 CFR alinéa J concernant les produits laser de

Classe I (1). Pour les autres pays : cette imprimante répond aux

normes IEC 60825 relatives aux produits laser de Classe I.

xiv Service Manual

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4023-001

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825.

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe

Avisos so bre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825 para productos láser de Clase I (1).

Spanish

Italian

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanóme tros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel de

Notices and Safety Information xv

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4023-001

la Clase I durante su uso normal, el mantenimiento realizado por el

usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformid ade com os

requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a

Classe I (1) de produtos laser. Em outros locais, está certif icada

como um produto laser da Classe I, em conformidade com os

requisitos da norma IEC 60825.

Os produtos laser da Classe I não são considerados perigosos.

Internamente, a impressora contém um prod uto lase r da C lass e IIIb

(3b), designado laser de arseneto de potássio, de 5 milliwatts

,operando numa faixa de comprimento de onda entre 770 e 795

nanómetros. O sistema e a impressora laser foram concebidos de

forma a nunca existir qualquer possiblidade de acesso humano a

radiação laser superior a um nível de Classe I durante a operação

normal, a manutenção feita pelo utilizador ou condições de

assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een

laserprodukt van klasse I. V oor de Verenigde Staten zijn deze eisen

vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in

IEC 60825.

Dutch

Portugese

Laserproduk ten van klasse I worden niet als ongevaarlijk

aangemerkt. De printer is voorzien van een laser van klasse IIIb

(3b), dat wil zeggen een gallium arsenide- laser van 5 milliwatt met

een golflengte van 770-795 nanometer. Het lasergedeelte en de

printer zijn zo ontworpen dat bij normaal gebr uik, bij onderhoud of

reparatie conform de voorschriften, nooit blootstelli ng mogelijk is

aan laserstraling boven een niveau zoals voorgeschreven is voor

klasse 1.

xvi Service Manual

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Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelse r.

Danish

Notices and Safety Information xvii

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4023-001

Huomautu s las er laitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS

21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I

laserlaitteiden IEC 60825 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle.

Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin

galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.

Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei

altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen

normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden

huoltotoimien yhteydessä.

LUOKAN 1 LASERLAITE

V AROITUS! Laitteen käyttäminen muulla kuin tässä käyttöohjeessa

mainitulla tavalla saattaa altistaa käyttäjän turvallisuusluokan 1

ylittävälle näkymättömälle lasers äteilylle.

KLASS 1 LASER APPARAT

VARNING! Om apparaten används på annat sätt än i denna

bruksanvisning specificerats, kan användaren utsättas för osynlig

laserstrål ning, som överskrider gränsen för laserklass 1.

Finnish

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina

näkymättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och

spärren är urkopplad. Betrakta ej strålen.

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Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwat t so m arbe t ar i våglängdsområdet 770795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för at t n ågon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserproduk t i samsvar med kravene i IEC

60825. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren

inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-ar senlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceopera sjoner.

Swedish

Norwegian

Notices and Safety Information xix

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Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora

compleix els requisits de DHHS 21 CFR, apartat J, pels productes

làser de classe I (1), i segons ha estat certificat en altres llocs, és un

producte làser de classe I que compleix els requisits d’IEC 60825.

Els productes làser de classe I no es consideren perillosos. Aquesta

impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li,

nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona

de 770-795 nanòmetres. El sistem a làser i la impressora han sigut

concebuts de manera que mai hi hagi exposició a la radiació làser

per s obre d’un nivell de classe I durant una operació normal, durant

les tasques de manteniment d’usuari ni durant els serveis que

satisfacin les condicions prescrites.

Catalàn

Japanese Laser Notice

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Chinese Laser Notice

Korean La ser Notice

Notices and Safety Information xxi

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Safety Information

• This product is designed, tested and approved to meet strict

global safety standards with the use of specific Lexmark components. The safety features of some parts may not alway s be obvious. Lexmark is not responsible for the use of other 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 dur ing disassem bly and ser v icing of this product. Professional service personnel should understand this and take necessary precautions.

Consignes de Sécurité

French

• Ce produit a été conçu, testé et approuvé pour respecter les

normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiqu es. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange.

• Les consignes d'entretien et de répa ration de ce produit

s'adressent uniquement à un personnel de m aintenance 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.

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Norme di sicurezza

Italian

• Il pr odotto è stato progettato, testato e approvato in conformità a

severi standard di sicurezza e per l’utiliz zo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori.

• 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

German

• Dieses Produkt und die zugehörigen Komponenten wurden

entworfen und getestet, um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt 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.

Pautas de Seguridad

Spanish

• Este producto se ha diseñado, verificado y aprobado para

cumplir lo s más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean

Notices and Safety Information xxiii

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siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio.

• La in formaci ón 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 conscien te de este peligro y tomar las precauciones necesarias.

Informações de Segurança

Portugese

• Este produto foi concebido, testado e aprovado para satisfazer

os padrões globais de segurança na utilização de componentes específicos da Le xmar k. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serv iços e não de vem s er 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 necessári os.

Informació de Seguretat

Catalàn

• Aquest producte està dissenyat, compr ovat i apro vat per tal

d'acomplir les estrictes nor me s de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.

• La in formaci ó 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.

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El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.

Chinese

Korean

Notices and Safety Information xxv

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1. Gen e r a l Informat io n

Maintenance Approach

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, and service checks to determine the symptom and repair the failure. You may find that the removals in the Repair Information chapter w ill help you identify parts.

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

Tools

The removal and adjustment procedures described in this manual require the following tools and equipment:

• Magnetic tip Phillips screwdrivers, large and small

• Flat-blade screwdrivers

• Analog volt ohmmeter (a digital volt ohmmeter may also be

used)

• Needle nose pliers

• Tweezers, C-ring pliers

When you make voltage readings, always use frame ground unless another ground is specified.

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Serial Number

The serial number is located in the bottom left corner of the label

illustrated below:

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Abbreviations

ASIC Application-Specific Integrated Circuit CSU Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read-

Only Memo ry EP Electrophotographic Process ESD Electrostatic Discharge FRU Fi eld Replacea ble Unit HVPS High Voltage Power Supply LAN Local Area Network LASER Light Amplification by Stimulated Emission

of Radiation LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Vol tage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PICS Problem Isolation Charts PIXEL Picture Element POR Power-On Reset POST Power-On Self Test PQET Print Quality Enhancem ent Technology RIP Raster Image Processor ROS Read-Only Storage SRAM Static Random Access Memory UPR Used Parts Replacement VAC Volts alternating current VDC Volts direct current

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Standard Feat ures

Printer (Main)

Feature Description

Print speed 35 ppm (letter/A4) High Speed Printing Power supply AC120V, AC220–240V ±10% Power

consumption Tempera tur e 10 to 35°C Controller Lexmark Control ler (High Performance) RIP page

storage Printer

management software

Operator panel Operator panel access for menus Universal Drawer 250 sheet 11x17/A3/letter/legal/ A4 500 sheet input

drawers Copy collation Multiple copy collation in the printer RAM Dimensions 1.75 ft. (535 mm) Width x 2.06 ft. ( 628 mm) Depth x 1.40

Printing system Electrostatic dry powdered imaging system +

Exposure system Laser diode + polygon m irror scanning Paper feeding

system

1200W 45W or less (low power)

Hard disk option can be partitioned to be used for intermediate RIP page storage

Markvision management

Two (2) 500 sheet input drawers (11x17/A3/letter/legal/ A4)

ft. (428 mm) Height

Imaging cartridge Two-com ponent imaging cartridge

Six-way system Tray 1 (multipurpose) (250 sheet s)

for network and/or desktop printer

Charging system Comb electrode with scorot ron system Development MTHG system Density

correction Density control Developing bias adj usting system

ATDC sensor

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Feature Description

Image transfer system

PC drum Organic photoconductor (OPC) Cleaning system Blade system Separating

system Fusing system Heat roller fusing system Paper exit

system

Roller t ransform system

Paper separator

Printer

Face do wn (300 sheets maximum A4/C/Lett er C)

Mailbox

2000 sheets

Finisher

2500 sheets

500 sheets standard bin 2000 sheets fini sher bin

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Options

Option Description

EDO DRAM Memory Options:

Hard disk Hard disk option

Tri-port interface card

MarkNet Adapters

Parallel connector

Paper handling 500 sheet input tray and drawer

OptraImage

32MB EDO Memory 64MB EDO Memory

Hard disk adapter cable Serial, LocalTalk and IR A,B,C

Token-ring Ethernet (10BT/100BTx) Ethernet (10BT/2) Ethernet (10BT/100BTx) SCSI Coax/twinax adapter for SCS

Parallel/USB A,B,C

2500 sheet input tray (worldwide) 2000 sheet mailbox 2500 sheet finish er (3 and 4 hole

punching capability, 5k stapling capacity)

Ethernet 10/100, SCSI scanner and fax

Optra W810 Versions*

A,B,C

B,C

A,B,C

Supplies Photoconductor kit

Toner cartridge Staples

Cables 10-foot par allel cable

20-foot par allel cable 50-foot serial cable 10-foot 1284 A-C parallel cable

*Versions are: A–W810 B–W810n C–W810dn

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Printer/Options

Parts Identification

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Printer Configuration

The following diagram shows the major parts of the printer and paper path. The printer consists of the paper feed section, printhead unit (exposure section), imaging cartridge (charging section and development section), image transfer section, fusing section, cleaning section and paper exit section.

1 Paper Exit Roller 12 Double Feed Sensor 2 Paper Exit Sensor (PS3) 13 Tray1 (1st Paper Cassette) 3 Lower Fusing Roller 14 1st Paper Cassette Near Empty Sensor

4 Upper Fusing Roller (Heater Lamp) 15 1st Paper Cassette Empty Sensor (PC4) 5 Image Transfer Roller 16 ATDC Sensor 6 Synchronizing Roller 17 Sleeve Roller 7 Synchronizing Roller Sensor (PC2) 18 P C Drum Charger 8 Manual Unit 19 PC Drum 9 Tray2 (2nd Paper Cassette) 20 Imaging Cartridge 10 2nd Paper Cassette Near Empty Sensor

(PC25)

11 2nd Paper Cassette Empty Sensor (PC22) 22 Laser Beam

(PC5)

21 Print Head Unit (PH)

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General Des crip tio n of Each Sectio n

Paper Feed Section

Paper feeds from tray 1 (1st paper cassette), tray 2 or 3 (500-sheet paper cassette). When the printer receives a print command, the transport motor M2 turns, paper take-up solenoid turns ON, and the paper take-up roller in the 1st paper cassette feeds a sheet of paper. The synchronizing roller sensor (PC2) detects the fed paper and the paper is then fed to the synchronizing roller fo r printing. When paper trays (500-sheet cassette (tray 2 or 3), 250-sheet universal cassette (tray 1)), or 2500-sheet drawer is installed, paper feeds from the respective paper source.

Printhead Unit (Exposure Section)

The laser diode in the printhead unit emits a laser beam. The scanning beam creates an electrostatic latent image on the surface of the PC drum in the imaging cartridg e.

Imaging Cartridge (Charging, Development Section)

The imaging car tr idge consist s of the charging section and development section. The I/C drive motor (M1) drives the moving parts of the imaging cartridge.

Image Transfer Section (Release Section)

The toner image on the PC drum transfers to the paper when passing over the transfer roll. The paper electrostatically releases from the PC drum.

Fusing Section

Using a heated roller , the fusing section permanently fixes the toner image onto the paper. A heat sensitive element (thermistor) attached to the upper fusing roller controls the fusing temperature.

Cleaning Section

The cleaning blade removes excess toner from the paper and transfers the toner to the waste toner box.

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Paper Exit Section

After the paper passes the fusing section, the paper exit roller ejects the paper out the top of the printer. The paper exit sensor (PC3) senses the ejection of the paper.

Optional manual and duplex unit installed:

The duplex unit switchback motor pulls the trailing edge of the printed paper inside the duplex unit. The duplex unit transport motor then feeds the paper to the manual unit where the paper remains until the second print command.

General Flow for Printing Process

Print command Polygon Motor ON

Cleaning The transfer roll er becomes negatively

Starting processing The I/C (imaging cartridge) drive motor (M1) Paper take-up The transport motor (M2) starts turning.

Laser emission A laser beam is emitted at constant power. Scanning the image dat a

Paper feeding

Dev eloping the image data T one r is applied to the PC drum to produce a Transfer the image data The toner image on the surface of the PC Fusing the toner The toner is permanently fixed onto the Cleaning Excess toner and electric potential on the Paper ejection The paper ejects.

The motor in the printhead unit starts turning.

charged to prevent the negat ively-charged toner from sticking to the PC Drum.

starts turning.

The paper take-up solenoid turns on to feed paper.

A laser beam scans the sur face of the PC drum to produce a latent elect rostatic image.

The syc hroniz ing r olle r sen sor (PC2) d etects the presence of paper. The sychronizing clutch then turns on which turns on the sychronizing roller for feeding paper.

visibl e toner image. drum is transferred onto the paper. paper. PC drum are eliminated .

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Paper Feed Section

Taking Up Paper–Tray 1 (1st Paper Cassette)

Power is transmitted from the transport motor (M2) as follows to take up paper from the 1st paper cassette:

1. The transport motor (M2) tur n s counterclockwise.

2. The idle gear turns clockwise and the 1st cassette paper takeup solenoid (SL1) turns ON.

3. The paper take-up roller turns counterclockwise and paper is taken up.

1 PC Drum 5 Synchronizing Roller 2 Image Transfer Roller 6 Paper Take-Up Roller 3 Transport Motor (M2) 7 Paper 4 Synchronizing Roller

Sensor (PC2)

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Tray 1 Sensors

1 1st Cassette Paper Near Empty Sensor (PC5) 5 Synchronizing Roller Sensor (PC2) 2 1st Cassette Set Sensor (PC6) 6 Double Feed Sensor 3 1st Cassette Paper Take-up Solenoid (SL1) 7 Paper Take-up Roller 4 Separator Pad 8 1st Paper Cassette Empty Sensor (PC4)

1st Cassette Tray 1 Set Sensor (PC6)

PC6 (1) sensor detects installation of the 1st paper cassette in tray

1 1st Cassette Set Sensor (PC6) 2 1st Paper Cassette

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1st Cassette Tray 1 Paper Empty Sensor (PC4)

PC4 (1) detects paper empty status of the 1st paper cassette. .

1 1st Paper Cassette Empty Sensor (PC4) 2 Paper

1st Cassette Tray 1 Paper Near Empty Sensor (PC5)

PC5 detects when the 1st cassette is near empty.

1 1st Paper Cassette Near Empty Sensor (PC5) 2 Paper 3 Paper Lifting Plate

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1st Cassette Tray 1 Double Feed Sensor

The double feed sensor (located on the double feed detecting sensor board (PWB-H)) detects the possibility of double feed. This sensor uses a photo reflector.

The double feed sensor detects whether the leading edge of paper to be taken up next runs 10 mm or more from the paper nip point. If paper runs 10 mm or more, double feeding may occur if the paper is taken up in the normal printing interval. To avoid this, the printer prolongs the printing intervals as long as the double feed sensor detects a double feed status. This results in the reduction of the number of sheets fed per minute.

Light reflects: Output=L Light does not reflect: Output=H

1 Paper 2 Paper Take-up Roller 3 Double Feed Sensor

1st Cassette Tray 1 Synchronizing Roller Sensor (PC2)

This sensor detects that the paper is fed inside the printer.

1 Synchronizing Roller Sensor (PC2) 2 Paper

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1st Cassette Tray 1 Paper Size Detection

Five DIP switches indicate the paper size for the 1st paper cassette. Four of the switches indicate length and one width. The DIP switches are located on the 1st cassette paper size board (PWBS1).

The ON(1)/OFF(2) settings of the length dip switches set the analog input voltage. The input voltage and the normal input data from the width dip switch port determine paper size.

The precise paper size cannot be identified by detection and must be selected from the operation panel.

When no cassette is set, all switches are set to off.

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Tray 2 (2nd Paper Cassette)

1 2nd Cassette Paper Empty Sensor (PC22) 4 2nd Cassette Right Door Detecting Sensor 2 2nd Cassette Paper Near Empty Sensor (PC25) 5 Paper Take-Up Roller

3 2nd Cassette Paper Take-up Solenoid (SL21)

(PC23)

Taking up Paper–Tray 2 (2nd Paper Cassette)

Power transmits from the transport motor (M2) as follows to take up paper from the 2nd paper cassette:

1. The transpor t motor (M2) turns counterclockwise.

2. The idle gear turns clockwise.

3. The 1st cassette paper take-up gear turns counterclockwise.

4. The 1st cassette idle gear turns clockwise and the transport clutch (CL1) turns ON.

5. Power is transmitted to the 2nd paper cassette. a. The 2nd cassette paper take-up solenoid (SL21) turns ON. b. Paper take-up roller turns counterclockwise. c. Paper is taken up.

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1 PC Drum 6 Paper 2 Image Transfer Roller 7 Paper Take-up Roller 3 Transport Motor (M2) 8 Transport Clutch (CL1) 4 Synchronizing Roller Sensor

(PC2)

5 Transport Gear

9 Synchronizing Roller

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Tray 2 Sensors

2nd Cassette Detection

This sensor detects installation of the 2nd paper cassette in tray 2. The paper size indicated by the 2nd cassette paper size board

(PWB-S2, -S3) is also checked. The length dip switch setting determines paper size.

2nd Cassette Paper Empty Sensor (PC22)

PC22 detects the paper empty status of the 2nd paper cassette. Paper empty status occurs when paper runs out in the 2nd paper cassette.

1 2nd Cassette Paper Near Empty Sensor (PC22) 2 Paper

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2nd Cassette Paper Near Empty Sensor (PC25)

PC25 detects paper near empty status of the 2nd cassette.

1 2nd Cassette Paper Near Empty Sensor (PC25) 3 Paper Lifting Plate 2 Paper

2nd Cassette Right Door Detecting Sensor (PC23)

PC23 detects if the 2nd cassette right door is open or closed. The right door is normally closed except when removing jammed paper.

1 2nd Cassette Right Door Detecting Sensor (PC23) 2 Right Door

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Edge Guide and Trailing Edge Stop

Universal Cassette/500-Sheet Tray 2 & 3

The edge guide and trailing edge stop of the universal cassette slide to accommodate different paper sizes.The edge guide and trailing edge stop of the fixed paper size cassette are attached in fixed positions.

Fixed Paper Size Cassette

Paper Lifting Plate

Two paper lifting springs in each cassette constantly raise the paper lifting plate.

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Cassette-in-Position Detection

The rib on the cassette frame presses the cassette set switch on the back panel of the printer, indicating the cassette is inserted. The position of the rib on the cassette frame is different between the fixed paper size and universal cassette. This lets the printer detect which cassette is inserted.

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Paper Near Empty Detection

Height of the paper lifting plate determines paper-near-empty condition. Since the amount of paper available during the take-up sequence varies, detection occurs when the paper take-up roll is in the retracted position.

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Paper Empty Detection

When the cassette runs out of paper, the actuator of the paper empty sensor drops into the cutout of the paper lifting plate. This exposes the sensor, signaling that the cassette is out of paper.

General Information 1-23

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Paper Separating Mechanism

Each cassette has fingers that separate the top sheet of paper from the rest of the paper stack during paper take-up. When the paper take-up roll starts to turn, the turning force transmits to the top sheet of paper. The transmitted force overcomes the block of the fingers, causing the top sheet of paper to ride over the fingers and feed out of the cassette into the printer. The paper transport force obtained through friction with the top sheet of paper is weak and does not allow the second sheet of paper to ride over the block of the fingers.

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Paper Take-Up Roll

Two paper take-up rolls are mounted in both the fixed paper size cassette and universal cassette. As the take-up solenoid energizes, the spring tension increases, meshing the drive and clutch gear which transmits drive to the paper take-up rolls.

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Paper Feed

The paper taken up by the paper take-up section feeds to the transfer section after registration compensation.

Registration Compensation

Registration compensation eliminates paper skew by controlling the paper take-up roller and synchronizing roller rotation timing.

The taken-up paper passes the synchronizing roller sensor (PC2) and reaches the synchronizing roller. The printer delays the synchronizing roller to align the leading edge of the paper with the stopping synchronizing roller. The leading edge of the paper slacks a little as shown in the figure. The synchronizing clutch (CL1) activates and the paper take-up roller turns for a moment to securely feed the paper to the inside of the printer.

1 Slack of Paper 4 Synchronizing Roller Sens or (P C2) 2 Synchronizing Roller 5 Paper 3 Transport Motor (M2) 6 Paper Take-up Roller

Paper Feeding

1. The transpor t motor (M2) turns counterclockwise.

2. The idle gear turns clockwise. The synchronizing clutch (CL1) turns. The I/C drive motor (M1) drives the PC drum.

As the PC Drum turns, the transfer roller also turns.

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The synchronizing roller feeds paper to the PC drum and transfer roller. The PC drum and transfer roller pinch the paper and feed it to the fusing section.

1 PC Drum 4 Synchronizing Clutch (CL1) 2 Image Transfer Roller 5 Paper 3 Transport Roller 6 Synchronizing Roller

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Printhead Unit (Exposure section)

The printhead unit incorporates a laser diode that emits a laser beam corresponding to the print image data.

The scanning laser beam scans the PC drum from left to right, producing an electrostatic latent image on the surface of the PC drum.

Imaging Cartridge (Charging/Development Section)

The printer main body I/C drive motor (M1) transmits power to the gears of the imaging cartridge. The I/C drive motor (M1) turns clockwise (as viewed from the front of the printer).

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Part Name Function

1 Waste toner box Collects excess toner. 2 Transf er screw Transfers exc ess toner to the

3 Rotary blade Transfers the waste toner

4 Separating claw Ensures paper release fro m the

5 Cleaning blade Removes excess toner from the

6 Sheet erase Negatively charges the PC Drum

7 PC drum Charged roller that applies image

8 Sleeve roller Transfers toner to the su rface of

9 Screw Mixe s toner and carrier inside the

10 ATDC Sensor Adjusts the toner density.

waste toner box.

collected by the cleaning blade to the waste toner box.

PC Drum.

PC Drum (waste toner) aft er transfer to the paper.

to eliminate the remaining elect ric polarity after tr ansfer to the paper.

to paper.

the PC Drum via a rotating resin sleeve and then dev elops it.

toner hopper.

11 Toner fil ler opening Toner is supplied from the sub-

hopper.

12 Charger Charges the PC Drum.

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Development Section

Development

The development section feeds toner to the electrostatic latent image on the surface of the PC drum to produce a visible toner image.

A screw circulates the toner in the toner hopper. The toner mixes with the carrier to produce the developer. The ATDC sensor detects the ratio of toner to carrier, and voltage controls the toner density. The developer is then supplied to the sleeve roller.

The sleeve roller negatively charges the toner. The toner adheres to the electrostatic latent image due to the reduced negative voltage in the image area. The toner does not adhere to the area where the laser beam has not been applied. This occurs because the charge brush maintains the negatively charged voltage in the non-image area.

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1 Laser Beam 4 ATDC Sensor 2 PC Drum 5 Screw 3 Sleeve Roller 6 Developer

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Toner Empty Detection

Three empty-toner conditions are detected: sub-hopper empty, toner bottle near empty, and toner bottle empty.

Sub-Hopper Empty

The toner detection plate lead switch checks the toner level by detecting the position of the toner detection plate.

The toner bottle supplies toner to the rotating mixing plate. The rotating mixing plate spreads the toner evenly in the sub-hopper . The toner pushes upward on the toner detection plate. The position of the toner detection plate indicates the amount of toner in the subhopper.

A toner empty status occurs when the toner detection plate lowers enough for the lead switch to detect the plate. However, the lead switch is not activated when the toner supply motor stops or the bottle motor rotates. When the sub-hopper empty status occurs, the bottle motor activates to supply toner to the sub-hopper from the toner bottle.

1 Toner Detection Plate 3 Rotating Mixing Plate 2 Toner Detection Plate Read

Switch

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Toner bottle near empty

The toner bottle empty status is detected when the toner bottle rotates and feeds toner to the sub-hopper. The bottle rotation counter checks the number of bottle rotations. If the number of rotations exceeds 10, the near empty status occurs. The bottle supplies toner after the near empty status occurs.

Toner bottle empty

The toner bottle empty status in the imaging cartridge occ urs when the ATDC sensor detects a toner density (ratio of toner to carrier) below 10%. When this occurs, the appropriate toner density cannot be maintained. The bottle motor and toner supply motor stop. The toner empty status is recorded and will not reset until the toner cartridge is replaced.

A TDC Sensor

The developer, circulated by a screw, passes over the ATDC sensor. The sensor measures the ratio of toner to carrier (T/C ratio) in the developer . This ratio is converted to a charge and input to PWB-A. When the sensor detects a low T/C ratio, T/C recovery mode begins.

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Image Transfer Section (Release Section)

The transfer roller transfers the toner image on the surface of the PC Drum onto the paper.

Normally the paper separates from the PC drum without any outside interference. When the paper fails to separate from the PC drum, the separating claw releases the paper by force.

1 PC Drum 2 Image Transfer Roller 3 Paper

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Optical Erase

During the optical erase, light from the eraser lamp irradiates the PC drum, eliminating the negative charge applied by the cleaning blade during PC drum cleaning. This prevents blac k lines from being created on the front and rear ends and both sides of the image.

1 Cleaning Blade 2 Optical Erase

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Fusing Section

Fusing

Toner-transferred paper feeds from the transfer section to the fusing section when power from the transport motor (M2) transmits to the upper fusing roller.

The fusing roller heater lamp (H1, built in the roller) heats the upper fusing roller. The fusing roller thermistor (TH1) attached to the upper fusing roller controls the heater temperature. To ensure overheating does not occur, the fusing roller thermostat (TS1) and fusing roller heater lamp fuse (TF1) are connected in series to the heater lamp (H1). The heater lamp (H1) heats when an AC voltage is applied.

1 Separator 5 Upper Fusing Roller 2 Thermostat (TS1) 6 Paper 3 Thermistor (TH1) 7 Lower Fusing Roller 4 Heater Lamp (H1) 8 Guide

Temperature Control Using The Thermistor

The resistance of the thermistor (TH1) attached to the upper fusing roller varies with temperatures. When temperature rises, the resistance of the thermistor (TH1) decreases, and vice versa.

Thermostat (TS1) and Heater Lamp Fuse (TF1)

If an abnormal current flows into the heater lamp because of thermistor trouble and the upper fusing roller temperature reaches

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approximately 220°C, the contact of the thermostat automatically opens to shut off AC voltage. (As the temperature decreases, the contact of the thermostat closes again. However, once the thermostat activates, you must replace it with a new one.) The thermostat cannot respond quickly enough to protect against a sudden overload current. In this case, the heater lamp fuse blows to protect the heater lamp.

Fusing Temperature Control

The fusing section start s to warm up when the main switch turns ON. Preliminary rotation occurs for 20 seconds when the temperature of the upper fusing roller reaches 170°C (338°F). When the rotation stops, the temperature of the upper fusing roller is approximately 200°C (392°F) and warm-up is complete. (Warm-up takes approximately 1 minute.)

Fusing PPM Control

The sides of the fusing roller become excessively hot when small sheets of paper (paper width of 250 mm (9-3/4") or less) print continuously. When this occurs, "fusing PPM control" activates to maintain specific paperfeed intervals and prevent the roller from becoming too hot.

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Paper Exit Section

Paper Path Through Exit

Paper fed from the fusing section passes through the paper exit roller and ejects printed-side down out the top of the printer. The transport motor (M2) provides transmit power for feeding paper.

The paper exit sensor (PC3) detects paper eject. As paper passes through the sensor, it presses the sensor arm until the sensor arm end engages with the photointerrupter.

1 Paper Exit Sensor (PC3) 2 Paper

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1 Paper 6 Synchronizing Roller 2 Paper Exit Roller 7 Transport Motor (M2) 3 Paper Exit Sensor (PC3) 8 PC Drum 4 Lower Fusing Roller 9 Upper Fusing Roller 5 Synchronizing Roller Sensor (PC2)

Detection of a New Imaging Cartridge

The printer checks for a new imaging cartridg e when:

• The printer is turned on after installing a new imaging cartrid ge.

• With the printer turned on, the right door is closed after

replacing the imaging cartridg e.

The imaging car tr idge has an activating fuse. When the printer is turned ON, the fuse is blown and the PC drum counter clears, enabling detection of the image cartridge life. When power is turned OFF, the counter value is stored in the imaging cartridge EEPROM. When power is turned ON, the counter value is recalled from the imaging cartridge EEPROM to continue counting.

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Right Door Interlock Switch (S2)

The right door is normally closed. It is open when the imaging cartridge is replaced or jammed pape r is removed.

With the door closed, the projection of the right door presses the spring attached to the switch lever, turning the switch ON. When it is opened, the lever of the switch is released, turning the switch OFF.

1 Right Door 3 Right Door Interlocks 2 Projection 4 Spring

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Duplex Unit Option

Parts Identification

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Cross-Sectional View

1 Duplex Unit Transport Roller 1 3 Duplex Unit Transport Roller 2 2 Duplex Unit Transport Roll 1 4 Duplex Unit Transport Roll 2

Switchback Mechanism

Switchback Operation

To accomplish the switchback operation, the switchback motor reverses the rotational direction of the paper exit roller. The onesided print then feeds into the duplex unit. The drive of the switchback motor is transmitted through a gear train.

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Paper Exit Roller Drive Coupling Mechanism

When the duplex unit is mounted, the tip of the duplex unit lever raises the idle lever. This disconnects the printer drive (fusing roller) from the paper exit roller and connects the switchback motor drive.

Switchback Motor Control

The switchback motor is a two-phase stepping motor.

Transport and Dupl ex Paper Take-Up Mechanism

Transport and Duplex Paper Take-Up Operation

The transport and duplex paper take-up operations are performed by two pairs of duplex unit transport rollers/rolls and the manual feed paper take-up roll of the printer. The drive for these operations comes from the duplex unit transport motor and manual feed paper take-up clutch.

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Duplex Unit Transport Motor Control

The duplex unit transport motor is a two-phase stepping motor.

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Paper Deck 2500-Sheet (LCC) Option

Cross-Sectional View

1 Lift 2 5 Vertical Transport Roller 2 Paper Take-Up Roll 2 6 Vertical Transport Roll 3 Lift 1 7 Feed Roll 4 Paper Take-Up Roll 1 8 Separator Roll

Vertical Transport Drive Mechanism

Vertical Transport Drive Operation

The Vertical T r ansport Roller is driven by LCC (paper deck) transport motor (HMOT). The driving force of HMOT is transmitted via a gear train and registration clutch (RCL) to the vertical transport roller which feeds the paper from lift 1 or 2 to the printer. Because of the long paper path from lift 2, skew tends to occur in the paper fed from

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lift 2. To correct skew, RCL forms a loop in the paper between the separator roll and vertical transport roller.

Control of LCC Transport Motor HMOT

The printer main engine board energizes and de-energizes HMOT by sending signals to HMOT through the LCC (paperdeck) main board (PWB-A). HMOT is a DC motor .

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Paper Take-Up Mechanism

The paper take-up mechanism takes up a sheet of paper from the paper stack on each lift and feeds it to the vertical transport roller.

A paper take-up sequence occurs when drive from LCC Transport Motor HMOT transmits through take-up clutch 1/2 P1CL/P2CL to paper take-up roll 1/2. When lift 1 runs out of paper, paper feeds from lift 2.

A roll with a torque limiter prevents double feed of the last two sheets of paper. The roll is mounted beneath paper take-up roll 1 of lift 1.

Paper take-up roll 1 is active when paper is fed from lift 1. Both paper take-up roll 1 and 2 activate to perform the paper take-up

sequence when paper feeds from lift 2. During this sequence, paper empty sensor 1 PPS1 detects proper feed of paper through take-up roll 1.

The sheet of paper taken from lift 1/2 temporarily stops at the paper standby position sensor to minimize variations in the position of the leading edge of the paper. Separator clutch BCL transmits drive to the separator roll which moves the sheet of paper to the vertical transport section.

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Paper Take-Up From Lift 1

After Lift 1 completes lifting motion, paper take-up roll 1 takes-up and feeds a sheet of paper until the paper blocks paper standby position sensor S1. This serves as the standby position of the paper.

When the printer sends a paper take-up signal, the separator/feed rolls and paper take-up roll 1 transport s the paper up to registration sensor RSEN. After RSEN has been blocked, the paper moves a

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little further to reach the vertical transpor t roller, and forms a registration loop, before stopping.

The vertical transport roller transports the paper to the printer. When the trailing edge of the paper being transported by the vertical transport roller unblocks paper standby position sensor S1, the subsequent sheet of paper is transpor ted to the standby position and the LCC waits for the next paper take-up signal.

Registration clutch RCL de-energizes a given period of time after the trailing edge of the paper being taken up unblocks registration sensor RSEN. The next paper take-up signal transmits after the timer (which starts when the vertical transport roller rotates for the preceding sheet of paper) runs out.

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Paper Take-Up From Lift 2

After all sheets of paper have been taken up and fed from lift 1, lift 1 moves to the top level position to serve as part of the paper path for feeding paper from lift 2.

After the trailing edge of the last sheet of paper from Lift 1 unblocks paper empty sensor 1 PPS1, both paper take-up roll 1 and 2 turn.

Paper take-up roll 1 and 2 transports the sheet of paper until the paper blocks LCC take-up sensor PPS0.

Paper take-up roll 1 transports the paper located at PPS0 until the paper blocks paper standby position sensor S1. This is the standby position of the paper.

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After the printer sends a paper take-up signal, the separator/feed rolls and paper take-up roll 1 transports the paper until the paper blocks registration sensor RSEN. The paper travels a little further to reach the vertical transport roller and form a registration loop before stopping. The vertical transport roller transports the paper to the printer.

After the trailing edge of the paper transported by the vertical transport roller unblocks paper empty sensor 1 PPS1, paper take-up roll 1 and 2 transport the subsequent sheet of paper until the subsequent sheet of paper blocks PPS1.

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If PPS0 is unblocked and a sheet of paper is blocking PPS1, the sheet of paper blocking PPS1 transports to the standby position uninterrupted. LCC then waits for the next paper take-up signal.

Registration clutch RCL de-energizes a given period of time after the trailing edge of the paper being taken-up unblocks registration sensor RSEN. The next paper take-up signal transmits after the timer (which starts when the vertical transpor t roller rotates for the preceding sheet of paper) runs out.

Paper Take-Up Retry Control

To minimize the occurrence of paper misfeed due to a slippery paper take-up roll, separator clutch BCL energizes again if a sheet of paper fails to reach registration sensor RSEN within a given period of time after BCL first energizes.

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Paper Separating Mechanism

The paper separating mechanism employs a system with a torque limiter that is fitted to the separator roll shaft. It stops the separator roll when friction changes between the feed and separator rolls.

Paper Pressure Releasing Mechanism

When LCC is pulled out, the pressure release rail pushes the separator roll assembly downward, releasing the pressure between the feed and separator roll. The pressure release rail is located above the rail on the paper take-up end.

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Paper Take-Up Roll Retracting Mechanism

When LCC is slid out, the projection on the back of the LCC front cover disengages from the pressure release lever . This pushes the paper take-up roll upward, releasing pressure between the paper and paper take-up roll.

Edge Guides and Trailing Edge Stop

The trailing edge stop screws into position (not used for letter crosswise). Edge guides slide into any position you want.

Whenever the positions of the edge guides and trailing edge stop change, be sure to perform the paper size setting procedure. (See “Paper Size Setting” that follows.)

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Paper Size Setting

The paper sizes that can be set are A4 crosswise and Letter crosswise.

After the positions of the edge guides and trailing edge stop change, place the DIP switch keys on LCC main engine board PWB-A in the corresponding positions according to the current paper size

Note: Positions 3 and 4 are not used.

SW1 Letter Crosswise A4 Crosswise

1OFF ON 2OFF OFF 3OFF OFF 4OFF OFF

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LCC-in-Position Detection

The LCC is detected at its closed position when the light blocking plate located on the rear end of the right rail blocks LCC Set Sensor FRONT.

Lifting Mechanism

When the LCC is slid into the printer, the couplings engage. The LCC lift-up motor EMOT rotates forward and backward, turning the one-way gear and gear train to raise Lift 1 and Lift 2 respectively.

Lift 1 and 2 drive mechanisms each contain a one-way gear. When EMOT turns forward, drive transmits to Lift 1 and when the motor turns backward, drive transmits to Lift 2.

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Lifting Operations

LCC set sensor FRONT is blocked.

LCC lift-up motor EMOT turns forward raising lift

The paper stac k caus es the li gh t blo c ki ng pla te the pape r take-up roll 1 assembly to block lift-up sensor 1 LS1.

EMOT de-energizes and then energizes to start turning backward, raising Lift 2.

The paper stac k caus es the li gh t blo c ki ng pla te the pape r take-up roll 2 assembly to block lift-up sensor 2 LS2.

EMOT de-ener gizes.

Paper is consumed as print cycles run.

The paper take-up roll gradually lowers, unblocking the lift-u p Sensor.

EMOT energizes and the lift raises. This lifts the paper stack to block the lift- up sensor.

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Both lift 1 and 2 perform the following sequence of operations to maintain pressure between the paper and paper take-up roll.

1. Lift 1 and 2 ascends.

• LCC is slid into position.

• The lift-up sensor is unblocked while a paper take-up

sequence occurs with paper present on the lift.

2. Lift 1 and 2 stops.

• Lift-up sensor is blocked.

• The paper stack top level position is being corrected.

3. LCC lift-up motor EMOT energizes.

4. Lift 1 and 2 descends.

• LCC is slid out of the printer.

• Lift 1 and 2 are lowered.

Note: To absorb shocks that would otherwise be applied during the descent motion, springs are loaded in the rear side of the LCC.

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Paper Near Empty Detection

A paper-near-empty condition is detected by sensing the height of lift 1 or lift 2. When paper is used during a print cycle, lift 1 or 2 gradually moves up. This eventually unblocks the paper near empty sensor, indicating that the LCC (paper deck) is near empty.

Paper Empty Detection

Paper empty sensor 1 PPS1 and paper empty sensor 2 PPS2 (reflector-type photosensors), installed in the paper take-up unit, detect the paper-empty condition. When a paper-empty condition is detected, the corresponding message displays on the panel.

² When Paper is Loaded The light from the LED of paper empty sensor 1 PPS1 or paper empty sensor 2 PPS2 reflects ind cating that there is paper in LCC.

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² When Paper is Not Loaded The light from the LED of paper empty sensor 1 PPS1 or paper empty sensor 2 PPS2 does not reflect, indicating th ere is no paper loaded in the LCC.

Paper Dehumidifying Heaters

Paper dehumidifying heaters (mounted on both sides of the LCC) prevent paper passage performance from being degraded by damp paper during highly humid conditions. As long as the power cord is plugged in, these heaters are kept ON at all times.

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Mailbox/Transport Option

Parts Identification

Horizontal Transport Unit Cross-Sectional View

1 Paper Entrance Switching Mechanism 2 Upper Attachment 3 Transport Roller 4 Horizontal Unit Paper Sensor

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Paper Path

The path of the paper ejected from the printer varies with the paper output selection. Various sensors and switches check whether the paper travels properly in the designated path. The follo wing illustration shows the relationship between the paper path and sensors/switches.

In single-side printing, as the entrance of the horizontal transport unit moves up, the paper trav els into the horizontal transport unit and then into the storage unit, where the storage unit sorts the paper into the designated bin. If the paper has not passed the PC1 or PWB-C within a certain time after the printer paper exit sensor turns ON, the paper has jammed inside the horizontal transport unit or at the entrance/exit of the storage unit. This results in a jam error.

Paper ejects from the horizontal transport unit. The storage unit entrance roller then forwards the paper. The subsequent paper path varies with the paper output selection. The paper passes to the paper exit sensor (PWB-C), exit roller and arrives in the designated bin. If the paper has not reached/passed the paper exit sensor (PWB-C) within a certain time after the horizontal unit paper sensor (PC1) turns ON, the paper has jammed at the entrance/exit of the storage unit, causing a jam error.

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Paper Transport Mechanism

Entrance Path Switching Mechanism

Non-Sort mode: Paper entrance switching solenoid (SL1) energizes to swing the path

switching guide upward and stop it when non-sort tray transport position detecting sensor is blocked.

Mode other than Non-Sort: Paper entrance switching solenoid (SL1) energizes to swing the path

switching guide upward and stop it when finisher transport position detecting sensor is blocked.

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Paper Entrance Switching Mechanism

The paper entrance switching solenoid (SL1) energizes according to the selected mode (duplex or single-side), which moves the entrance of the horizontal transport unit up or down. The entrance of the horizontal transport unit moves down in duplex printing, and moves up in single-side printing. A tab interlocked with the paper entrance switching solenoid (SL1) turns ON/OFF the non-sort tray positioning sensor (PC2) and the sort bin positioning sensor (PC3), detecting the position of the entrance.

If the entrance moves up and down when the horizontal transport unit is not attached to the printer properly, the entrance may be damaged. To prevent this, a stopper is provided. If the horizontal transport unit is not attached to the printer properly, this stopper prevent the gears from engaging. As a result, drive force of the paper entrance transport motor (M1) in the printer does not transfer to the entrance.

Paper Transport Mechanism (Horizontal Transport Unit)

This mechanism transpor ts the paper from the horizontal transpor t unit to the storage unit. Drive force transfers from the storage unit transport motor (M1). Make sure that the gear at the exit of this mechanism engages with the gear at the entrance of the storage unit.

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Paper Entrance Transport Mechanism

The transport motor (M1) dr ives the horizontal transpor t rollers and entrance roller, transporting the print into the mailbox/finisher.

The paper ejects from the horizontal transpor t unit. The entrance roller guides the paper into the storage unit. The subsequent paper path varies with the paper output selection. In stacker mode, the 1st bin switching deflector moves down to close the downward paper path, forcing the paper toward the 1st bin. The paper then passes to the paper exit sensor, exit roller, and arrives in the 1st bin tray.

In mailbox mode, if a bin other than 1st bin is designated, the 1st bin switching deflector moves up, causing the paper to move down toward the 2nd and subsequent bins. For instance, if the 2nd bin is designated, the 2nd bin switching deflector moves down to close the downward paper path, forcing the paper toward the 2nd bin. The paper then passes to the paper exit sensor , e xi t roller, and arrives in the 2nd bin tray. The same applies to other bins. Bin switching deflectors move down when their corresponding solenoid turns ON.

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Paper Empty Detection

A paper empty detecting sensor board, provided for each bin, checks for presence of paper. When paper is not present in a bin, the corresponding sensor turns ON. Sensor boards act in pairs (one as the emitter and the other as the receiver) to perform the paper sensing function. For instance, in the case of the 2nd Bin, the light emits from the topside (emitter) of the PWB-D2 (3rd bin) to the underside (receiver) of the PWB-D1 (2nd bin). If paper is not present in the 2nd Bin, the sensor turns ON, indicating a paper empty. If paper(s) is present, the paper blocks the light, keeping the sensor turned OFF.

Paper Full Detection

Each bin contains a lever-type switch. When the height of the stacked papers exceeds a certain level, the paper pushes the lever up, turning the switch ON. The switch is attached to the underside of each paper empty detecting sensor board.

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Paper Output Modes

The mailbox has two paper output modes—stacker and mailbox.

Stacker Mode

The horizontal transport unit moves up and all papers output through the horizontal transport unit into the 1st bin.

Mailbox Mode

The entrance of the horizontal transport unit moves up and all papers output through the horizontal transpor t unit into the designated bin. Any bins from the 1st to 10th bins can be assigned as dedicated bins.

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Finisher Option

Parts Identification

1 1st Tray 6 Rear Cover 2 Upper Right Cover 7 Finisher Tray Cover 3 Misfeed Clearing Cover 8 Upper Rear Cover 4 Front Cover 9 Staple Door 5Elevator Tray

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Paper Transport Path Switching Mechanism

1st Tray/Finisher Tray Path Switching Mechanism

When the upper entrance switching solenoid energizes through PWM control, the print exits into the 1st tray. When the upper entrance switching solenoid de-energizes, the print exits toward the finisher tray.

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Paper Transport Mechanism

Paper Entrance Transport Mechanism

The transport motor (M1) drives the horizontal transport rollers and entrance roller which transports the print into the finisher.

1st Tray Tran spo rt Mechanism

Upper exit motor drives the 1st tray exit roller and transport roller to feed the print into the 1st tray. The speed at which the print transports decelerates as it feeds into the 1st tray.

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Upper Exit Motor Control

Changing the driving action varies the upper exit motor (M2) speed.

Punch Mec hanism

The print traveling through the finisher briefly stops, allowing the punch rods to punch the paper.

The transport motor and the electromagnetic spring clutch fitted to the punch roller energize and de-energize, moving the punch rods up and down to punch holes in the print.

Punch Operatio n

The print transports from the printer into the horizontal transport unit. M1 energizes to turn the horizontal transpor t rollers and entrance roller. At the same time, upper exit motor energizes to turn the transport roller. The trailing edge of the print moves past the paper sensor of the horizontal transport unit. After a given period of time, the upper exit motor deenergizes to stop the transport roller. The transport motor remains energized, forming a loop in the print before the transport roller. The electromagnetic spring clutch energizes causing the Punch Roller and eccentric cams to turn. The eccentric cams cause the punch rods to move up and down, punching holes in the print. The upper exit motor energizes again to feed the print into a tray or bin.

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Fini sher Tray

The finisher tray is used when aligning, shifting, and stapling a print set/stack in the shift or staple mode. The finisher tray and paper holding tray retract to let the processed print set/stack drop onto the elevator tray.

CD Aligning Mechanism

The CD aligning plate moves and the paddle rotates to press each print against the shift reference plate.

CD Aligning P l a te

The CD aligning motor rotates in the forward or backward direction, turning the spiral shaft to move the CD aligning plate.

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To ensure positive print aligning motion, the CD aligning plate moves from its home position to standby position before the print feeds into the finisher. The CD aligning plate moves between the standby and aligning positions until the last print is aligned. The CD aligning home position sensor detects the CD aligning plate home position. This position serves as the reference point for movement of the CD aligning plate. The standby position varies according to the paper size (CD length).

The standby position is 8.5 mm away from the print end face.

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CD Aligning Motor Control

The CD aligning motor sequences the movement of the CD aligning plate.

Paddle

The paddle moves the print, which has been fed by the CD aligning plate, toward the stapling corner. The gear is normally locked by the torque limiter and, when paddle motor turns forward, the paddle lowers. As the tension of the spring exceeds the force of the torque limiter, the rotation of the motor transmits to the paddle through the gear train.

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