Lexmark C910 Service Manual

C910 Color Printer

• Table of Contents

•Start Diagnostics

• Safety and Notices

• Trademarks

5055-01X

•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.

5055-01x

Edition: November 2001
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 WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties i n certain transactions; th erefore,
this statement may not apply to you.

This p ublic ation could inc lude technical inaccuracies or typographi cal erro rs. Ch anges
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 tim e.

Comments may be addressed to Le xmark International, Inc., Department D22A/032-2,
740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or electronically mailed
(e-mail) to [e-mail]. Lexmark may use or distribute any of
the information you supply in any way it believes appropriate without incurring any
obligation to you. You can purchase additional copies of publications related to this
product by calling 1-800-553-9727. In other countries, contact your point of purchase.

Lexmark and Lexmark with diamond design and OptraImage are trademarks of Lexmark
International , Inc., register ed in the U nited St ates and/or oth er countries.

Other trademarks are the property of their respective owners .

© Copyright Lexma rk Inte r na tion al, Inc. 20 01 .
All rights reserved.

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 Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 an d in applicable FAR pro visions: Lexmark International, Inc.,
Lexington, KY 40550.

U.S.A. P/N 12G9081

5055-01x

Contents

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

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

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

Standard Inspection and Cleaning Procedure . . . . . . . . . . . . . . . 1-1

Return Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Recommendations For Service . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Serial N umber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Processes and Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Electrophotography Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Development Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Transfer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Cleaning Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Paper Feeding / Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Paper Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Cassette Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Multi-P u rp os e Feeding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Registration Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Separation Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -12

Fuser U nit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -13

Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Belt Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -15

Belt Up/Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -16

Expansion Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Duplex Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -17

Printing Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -18

OHP Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Thick Paper Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Envelope / Postcard Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Clearing Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

High Capacity Paper Feeder (HCPF). . . . . . . . . . . . . . . . . . . . . 1 -25

Maintenance Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

High Capacity Paper Feed Sensor / Switch Test. . . . . . . . . . . . 1 -35

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Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Adjustments and Procedures Following Parts Replacement . . . .2 - 1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Initial Ch ec k. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Printer Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Service Error Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Attendance Messages g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Maintenance Analysis Procedures (MAPS) . . . . . . . . . . . . . . . .2-43

Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Drive 1 DC Motor Service Check . . . . . . . . . . . . . . . . . . . . . . . .2-55

Drive 2 Stepper Motor Service Check. . . . . . . . . . . . . . . . . . . . .2-55

Duplex Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

Expansion Paper Feed Service Check . . . . . . . . . . . . . . . . . . . .2-56

Face-Down Stacker Full Service Check . . . . . . . . . . . . . . . . . . .2-57

High Capacity Paper Feed (HCPF) Service Check. . . . . . . . . . .2-57

Operator Panel Service Check . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

Paper Carrying Service Check . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

Paper Exit, FU/FD Service Check. . . . . . . . . . . . . . . . . . . . . . . .2-63

Paper Tray Missing Service Check . . . . . . . . . . . . . . . . . . . . . . .2-63

Photodeveloper Missing Service Check . . . . . . . . . . . . . . . . . . .2-64

Power Supply Ser vice Check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-65

Marks on Paper Service Check. . . . . . . . . . . . . . . . . . . . . . . . . .2-66

Transfer Belt Up/Down Service Check . . . . . . . . . . . . . . . . . . . .2-68

Image Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69

Print Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69

Options Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Power-On Self Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Using the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Operator Panel Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Printing the Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Operator Menu Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Print Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Hardware Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Diagnostics - Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

Viewing and Resetting the Drum Counters . . . . . . . . . . . . . . . .3-22

Diagnostics - Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

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Repair Informatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Service Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

High Capacity Paper Feed Timing Belt Adjustment. . . . . . . . . . . 4-3

Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Cover, Top Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Cover, Front Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Cover, Front Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Cover, Rear Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Cover, Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Cover, Left Side Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Cover, Right Side Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Cover, RIP Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Tray, Paper Exit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

RIP Box Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Electronic Box Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

LED Printhead Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -12

Eraser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Printhead Controller Board Removal . . . . . . . . . . . . . . . . . . . . . 4-15

Upper Fan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -16

Multi-Purpose Feeder Tray Removal. . . . . . . . . . . . . . . . . . . . . 4 -17

Paper Feed Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Paper Carrying Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Paper Present Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4 -19

Paper Feed Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Cassette Guide Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Temperature/Humidity Sensor Removal . . . . . . . . . . . . . . . . . . 4 -22

Paper Feed Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4 -22

Paper Remaining Sensor Removal . . . . . . . . . . . . . . . . . . . . . . 4-22

Gear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Multi-Purpose Feeder Roll Removal . . . . . . . . . . . . . . . . . . . . . 4-23

Multi-Purpose Feeder Clutch Removal . . . . . . . . . . . . . . . . . . . 4-23

OHP Detection Sensor (Upper) Removal . . . . . . . . . . . . . . . . . 4-23

Fanning Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Registration Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Multi-Purpose Feeder Paper Present Sensor Remov al. . . . . . . 4-27

Paper Carrying Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . 4 -28

Paper Carrying Roller (Upper) Removal . . . . . . . . . . . . . . . . . . 4-28

Paper Carrying Clutch Removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-28

OHP Detection Sensor (Lower) Removal . . . . . . . . . . . . . . . . . 4 -28

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5055-01x

Registration Frame, Registration Clutch Removal . . . . . . . . . . .4-29

Transfer Belt Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Belt Up/Down Detection Sensor Removal. . . . . . . . . . . . . . . . . .4-34

Sensor Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

Density Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36

Separation Fingers Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36

Sensor Cleaner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36

Printer Controller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37

High Voltage Power Supply Board (HVU) Removal . . . . . . . . . .4-38

R Sub Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

Toner Remaining Sensor Removal . . . . . . . . . . . . . . . . . . . . . . .4-39

Drum Gear Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

Sub Frame F1, Sub Frame F2 Removal . . . . . . . . . . . . . . . . . . .4-40

Drive Gear Unit Sensor Assembly Removal . . . . . . . . . . . . . . . .4-41

Belt Up/Down Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-42

Power Supply 1 Remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Power Supply 2 Remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44

Drive Motor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Motor Drive Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Power Switch Remo va l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

Connector, Duplex Unit Removal . . . . . . . . . . . . . . . . . . . . . . . .4-47

Paper Size Sensor Board Assembly Removal . . . . . . . . . . . . . .4-48

Main Unit Fa n R emoval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49

Main Driv e Un it Re m o v al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50

Face-Up Paper Exit Assembly Removal . . . . . . . . . . . . . . . . . . .4-54

Face-Up/Down (Flapper Detection) Sensor Removal. . . . . . . . .4-54

Face-Up/Down Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . .4-54

Paper Delivery Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-54

Paper Exit Tray Switch Removal. . . . . . . . . . . . . . . . . . . . . . . . .4-54

Face-Down Guide Assembly Removal . . . . . . . . . . . . . . . . . . . .4-55

Paper Exit Motor & Full Sensor Removal . . . . . . . . . . . . . . . . . .4-55

Turn Guide Cover Sensor Removal . . . . . . . . . . . . . . . . . . . . . .4-57

Right Slide Rail Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-58

Front Cover Open Switch Actuator Removal . . . . . . . . . . . . . . .4-58

Lock Handle Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . .4-59

Top Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60

Stay Arm Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-61

Fuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62

Options Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-63

Expansion Paper Feeder Removal . . . . . . . . . . . . . . . . . . . . . . .4-63

Duplex Unit Separation Removal . . . . . . . . . . . . . . . . . . . . . . . .4-71

Duplex Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72

Duplex Timing Belt Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72

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Duplex Pressure Roller and Solenoid Removal. . . . . . . . . . . . . 4-73

Duplex Feed Roller And Solenoid Removal. . . . . . . . . . . . . . . . 4 -73

Duplex Side Fence Motor Assembly / Side Fence Removal . . . 4-74

Duplex Paper Carrying Motor Removal . . . . . . . . . . . . . . . . . . . 4 -75

HCPF Covers Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

HCPF Call Roller, Paper Feed Roller, Reverse Roller Removal 4-77

HCPF Pickup Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . 4 -78

HCPF Paper End Sensor Removal . . . . . . . . . . . . . . . . . . . . . . 4-79

HCPF Paper Size Sensors (1, 2) Removal . . . . . . . . . . . . . . . . 4-79

HCPF Tray Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -81

HCPF Paper Level Sensor Removal . . . . . . . . . . . . . . . . . . . . . 4 -82

HCPF Power Supply Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4 -83

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

Covers Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Major Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Printer C on t ro lle r Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Printhead Controller Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

RIP Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Power Source Unit 1 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Power Source Unit 2 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

High Voltage Power Supply Board. . . . . . . . . . . . . . . . . . . . . . . . 5-8

Sensor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Expansion Paper Feeder Controller Board . . . . . . . . . . . . . . . . . 5-9

Duplex Unit Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -10

Motor Drive Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -10

Size Sensor Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

High Capacity Paper Feed (HCPF) . . . . . . . . . . . . . . . . . . . . . . 5 -11

High Capacity Paper Feed Configuration. . . . . . . . . . . . . . . . . . 5 -12

Electrical Parts Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Driving Parts Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Sensor and Switch Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -15

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Maintenance Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Lubricants and Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

vii

5055-01x

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

How to Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

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

Assembly 2: Covers 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Assembly 3: Covers 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

Assembly 4: Covers 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

Assembly 5: Covers 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

Assembly 6: Upper Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

Assembly 7: Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Assembly 8: Base 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

Assembly 9: Base 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

Assembly 10: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24

Assembly 11: I/F Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

Assembly 11: I/F Controller (Continued) . . . . . . . . . . . . . . . . . . .7-30

Assembly 12: Fuser Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32

Assembly 13: Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34

Assembly 14: Expansion Feeder 1 . . . . . . . . . . . . . . . . . . . . . . .7-36

Assembly 15: Expansion Feeder 2 . . . . . . . . . . . . . . . . . . . . . . .7-38

Assembly 16: Duplex Unit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40

Assembly 17: Duplex Unit 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42

Assembly 18: High Capacity Paper Feed 1 . . . . . . . . . . . . . . . . .7-44

Assembly 19: High Capacity Paper Feed 2 . . . . . . . . . . . . . . . . .7-46

Assembly 20: High Capacity Paper Feed 3 . . . . . . . . . . . . . . . . .7-48

Assembly 21: High Capacity Paper Feed 4 . . . . . . . . . . . . . . . . .7-50

Assembly 22: High Capacity Paper Feed 5 . . . . . . . . . . . . . . . . .7-52

Assembly 23: High Capacity Paper Feed 6 . . . . . . . . . . . . . . . . .7-54

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x-1

viii Service Manual

5055-01x

Safety Information

Safety Notice

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

global safety standards with the use of specific Lexmark
components. The safety features of some parts may not
always be obvious. Lexmark is not responsible for the use of
other replacement parts.

• The maintenance information for this product has been

prepared for use by a professional service person and is not
intended to be used by others.

• There may be an increased risk of electric shock and

personal injury during disassembly and servicing of this
product. Professional service personnel should understand
this and take necessary precautions.

Consignes de Sécurité

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

normes strictes de sécurité globale lors de l'utilisation de
composants Lexmark spécifiques. 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 réparation de ce produit

s'adressent uniquement à un personnel de maintenance
qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

Safe ty In formation ix

5055-01x

Norme di sicurezza

• Il prodotto è stato progettato, testato e approvato in

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

• 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

• 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 Wart ung des

Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

x Service Manual

5055-01x

Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para

cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de Lexmark. Puede
que las características de seguridad de algunas piezas no
sean siempre evidentes. Lexmark no se hace responsable
del uso de otras piezas de recambio.

• La información sobre el mantenimiento de este producto

está dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.

Inform ações de Segurança

• Este produto foi concebido, testado e aprovado para

satisfazer os padrões globais de segurança na utilização de
componentes específicos da Le xma rk. As fu n ções de
segurança de alguns dos componentes podem não ser
sempre óbvias. A Lexmark não é responsável pela utilização
de outros componentes de substituição.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

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

Safe ty In formation xi

5055-01x

Informació de Seguretat

• Aquest producte està dissenyat, comprovat i aprovat per tal

d'acomplir les estrictes normes de se guretat 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 informació pel manteniment d’aquest producte està

orientada exclusivament a professionals i no està destinada
a ningú que no ho sigui.

• El ri sc d e xoc elèctric i de danys personals pot augmentar

durant el procés de desmun tatge i de ser vei d’aquest
producte. El personal professional ha d’estar-ne assabentat i
prendre les mesures convenients.

xii Service Manual

5055-01x

Safety In fo rmation xiii

5055-01x

xiv Service Manual

5055-01x

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. The removals in the Repair Information chapter
may help you identify parts.

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

Standard Inspection and Cleaning Procedure

• Switch off Printer power, and disconnect the AC power cord

from the wall outlet.

• Remove and inspect the photodevelopers and toner cartridges,

shielding them from strong light.

• Inspect the interior of the printer, removing foreign matter such

as paper clips, staples, pieces of paper/transparencies, paper
dust, hair, oil, grease or toner.

• Clean the printer interior using a lint-free cloth, dampened

slightly with cold water. Do not use solvents or chemical
cleaners to clean the printer interior.

• Use only the specified oil or lubricant on printer part s (some

service parts are pre-lubed from the factory).

• Inspect and, if necessary, clean all rubber/plastic and D rollers

with A lint-free cloth, dampened slightly with cold water. Dry the
rollers with a lint-free cloth.

• While cleaning, inspect the interior of the printer for damaged

wires, loose connections, toner leakage, loose springs, and
damaged or worn par ts.

• Be sure the printer is on a single, flat, strong table or desk top.

• Inspect all supplies (OCR, Cartridges, photodeveloper/toner

cartridges, belts, fuser CRUs) and paper sources (cassettes,
trays, feeders, duplex drawers, finishers, mailbox trays) for
obvious damage and proper installation (paper under corner
bucklers, paper guides not too tight) Inspect for correct media
usage (paper, transparencies, labels).

General Information 1-1

5055-01x

• Print a Demo page.

• If additional paper sources are installed, print a Demo page

from each of these, (if possible).

Note: Failure to print from an additional tray or feeder may imply
one or more pins are bent in the mating connector.

Return Parts

Engineering periodically analyzes returned parts for failure modes.
Please Include a printed test (DEMO) page, before and after the
repair, and tag any returnable parts with a description of the failure.

Recommendations For Service

Before leaving the printer check the following:

• Be sure printer is on a single, flat, strong tabletop. This is very

important for color printers that use belts. Check and set
registration as necessary.

• Shake all cartridges and be sure they are correctly installed and

fully seated.

• While the cover is open, wipe any residual toner from the LEDs

using a lint free cloth.

Tools

The removal and adjustment procedures require the following tools
and equipment:

• Magneti c t ip Phillips screwd rivers, large and sm all

• Flat-blade screwdrivers

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

used)

• Needle nose pliers

• Tweezers, C-ring pliers

• Magnifier (10 times or equivalent)

• 6-angle wrench (1.5 mm)

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

1-2 Service Manual

5055-01x

Serial Number

Open the front door, the serial number is located as shown. The
serial number is also on the menu settings page you can print from
the Test s Menu.

General Information 1-3

5055-01x

Abbreviations

ASIC Application-Specific Integrated Circuit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EPROM Erasable Programmable Read-Only Memory
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LAN Local Area Net work
LASER Light Amplification by Stimulated Emission of

Radiation
LCD Liquid Cr ys tal Display
LED Light-Emitting Diode
LVPS Low Voltage 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 Enhancement Technology
RIP Raster Image Processor
ROS Read-Only Storage
SRAM S t atic Random Ac cess Memo ry
UPR Used Parts Replacement
V ac Vol ts alternating current
V dc Volts direct current

1-4 Service Manual

5055-01x

Processes and Configuration

In this printer, the toner of four colors (magenta, cyan, yellow and
black) melts and deposits on paper, dots which record color image
information. This printing process is called the electrophotography
process.

Electrophotography Process

In the electrophotography process, electrically charged toner,
exposes, develops, transfers, and is cleaned with an aluminum
photosensitive drum. A photoconductive layer forms on the surface
of the drum when the drum is exposed to light.

The surface of the photosensitive drum is negatively charged,
forming the electrostatic image on the surface of the photosensitive
drum. This charge is directed to the photosensitive medium at a low
voltage, reducing the generation of ozone to a very low level. When
the drum surface is charged, the image is recorded by irradiating
light from the LED printhead, forming the electrostatic image. The
LED printhead array along with the Selfoc lens array provide a
single-dot line of the image, in a one-to-one arrangement. The
image data from the printhead controller causes the LED to emit
light in black dots. These black dots form an image of dots on the
photosensitive drum.

The LED printhead minimizes the displacement of images during the
color print process, when images of multiple printheads overlap,
causing dot position accuracy to be much higher. Since light from
the volume of the LED array varies depending on the LED
printheads, the light emitting value is recorded in the EPROM of the
printer controller. When the LED printhead is replaced, the light
emitting value should be entered for each printhead while the printer
is in maintenance mode.

Since the LED printhead and EPROM on the printhead controller
board of this printer are paired, the EPROM on the printhead
controller board should also be replaced whenever the printhead is
replaced.

General Information 1-5

5055-01x

Development Unit

Ton er forms the electrostatic image on the photosen sitive drum
during exposure. The single component, non-magnetic toner and the
lusterless color toner are weather-resistant, and fade little under
ultraviolet rays. This is helpful in saving documents.

Toner in the hopper is agitated and supplied to the development roll
by the supply roll. A (conductive rubber) doctor blade is fitted to the
development roll. Toner enters between the development roll and
doctor blade by the rotating dev elopment roll and is negatively
charged, forming the electrostatic image on the photosensitive
drum. Toner attaches to the bright portion of the photosensitive drum
per the voltage of the development roll.

Transfer Unit

Paper feeds electrostatically by the transf er bel t and is carried to the
transfer unit which turn at the speed of the photoconductor drum. A
charge roller applies a positive charge to the paper. The toner image
formed on the photoconductor drum is transferred to the paper from
the back side by the positive dc voltage applied to the transfer sheet,
which is in contact with the paper through the transfer belt.

1-6 Service Manual

5055-01x

Cleaning Unit

Toner remaining on the photosensitive drum following transfer, is
scraped away with the cleaning blade, and collected in the recovery
bag as waste toner. Residual toner on the photosensitive medium is
removed by the eraser.

Paper Feeding / Fusing

The main unit drive is composed of drives 1 and 2. Drive 1 feeds
paper, stands by, drives the belt unit, separates, fuses, feeds the
face-up delivery unit, and drives the photodeveloper and toner
cartridge by rotations of the dc motor. Drive 2 drives the face-down
delivery unit by rotations of the stepper motor.

The expansion paper feeder and the duplex unit use independent
motors to drive the paper delivery unit.

General Information 1-7

5055-01x

Drive System

Drive 1, composed of a 100 dc motor and gear unit, feeds the
registration paper from the paper feeder and drives the belt unit,
photodeveloper / toner cartridge, fusing unit, and face-up delivery
unit. The motor rotates by the ON signal from the printer controller/
motor drive unit and sends a rotation synchronization detection
signal to the motor drive unit.

Note: The gear unit of drive 1 is adjusted in phase and should not
be disassembled.

Drive 2, composed of a hybrid stepping motor and gear unit, drives
the face-down delivery unit.

1-8 Service Manual

5055-01x

Paper Feeding

The paper feeder is a two-way system composed of the multi-paper
feeder (100 sheets maximum) and an integrated 550 sheet tray).
Optionally, the expansion paper feeders (550 sheets) can be
increased to four layers. A high capacity paper feeding system
(3,000 sheets) may be used. Combining the multi-paper feeder,
expansion paper feeders, and high capacity paper feeding system
the printer has a maximum paper supply of up to 5,850 sheets.

Cassette Paper Feeder

The paper feeding solenoid turns on by the signal from the printer
controller. The paper feeding roller interconnected with drive 1,
rotates with the spring clutch and picks the paper in the paper
cassette.

General Information 1-9

5055-01x

Multi-Purpose Feeding

The multi-paper feed solenoid turns on by the signal from the printer
controller. The multi-purpose feed roll interconnected with the drive 1
through the spring clutch, rotates and picks the paper in the multi­purpose feeder.

1-10 Service Manual

5055-01x

Registration Unit

Media temporarily stops (registration) when adjusting the paper
leading edge parallel with that of the image, or when adjusting the
timing with the black image.

The upper and lower registration rolls are arranged in parallel with
the photosensitive drum for blac k imaging. The lower registration roll
incorporates a registration clutch which feeds or stops the paper.

In the forward direction of the registration roll, a registration sensor
(photo interrupter) is provided to detect paper fed from the paper
feeder and to stop paper jam feeding.

General Information 1-11

5055-01x

Separation Unit

The transfer belt and paper are separated with the belt drive roll by
separation fingers.

1-12 Service Manual

5055-01x

Fuser Unit

By applying heat and pressure, the image is melted and fused to the
paper.

The upper and lower rollers are heated and pressure-fitted. A heater
is positioned in the roller tube and a thermistor and therm ostat
remain in contact with the outside of the tube. Separation fingers are
attached near the upper roller to separate the paper from the roller .

Each thermistor sends the surface temperature of the roller to the
printer controller. The printer controller turns the heater on or off
according to the voltage of each thermistor. If the controller f ai ls and
the temperature of the roller exceeds specifications, the temperature
fuse (TCO) connected to each heater opens, preventing
overheating.

General Information 1-13

5055-01x

Delivery

After completing the fusing process, paper is discharged from the
printer. The delivery sensor detects the paper condition and the
FU/FD deflector switches between the face-up and face-down paper
delivery. The paper from the fuser pulls down the sensing lever
turning on the delivery sensor (photo interrupter). If the delivery unit
remains on longer than specified, the printer controller determines
that the printer is jammed, and the paper delivery flap lever switches
to either face-down or face-up.

1-14 Service Manual

5055-01x

Belt Unit

After passing through the registration unit, paper is electrostatically
fed by the transf er belt through the positively charged feed rol l at the
inlet of the belt unit and fed by the running belt. The belt runs at the
same speed as the photosensitive drum causing the image on the
C, M, Y and K developer to transfer to paper.

Since the photosensitive drum has a small diameter and the paper is
electrostatically fed by the transfer belt, the paper is easily
separated, after toner image transfer, and fed to the next developer.
Excess toner is scraped from the drum with a cleaning blade and
recovered into the waste toner bottle.

Adjust the registration when the belt unit is replaced. The
registration is adjusted at the leading edge of the image or by
adjusting the color image. This should be adjusted in maintenance
mode, when the belt unit is replaced.

The transfer belt is conductive and seamless. If the transfer belt is
damaged, toner can cling to the belt and contaminate the paper.
When fingerprints or other stains appear on the belt, wipe them
away with a dry cloth or cloth moistened with alcohol.

A density sensor is positioned facing the belt drive roller for
automatic density adjustment and registration adjustment. A
mechanism is provided to clean the sensor surface, which is
interconnected with the opening and closing of the front cover.

General Information 1-15

5055-01x

Belt Up/Down

In monochrome printing, switching to color printing is not required.
To avoid unnecessar y wear of the photosensitive drum by the
cleaning blade, this operation is stopped with the electromagnetic
clutch in drive 1. The transfer belt is lowered so as not to touch the
photosensitive drum during color printing.

The transfer belt moves up and down with the switching shaft cam by
the electromagnetic clutch in drive 1. The belt position is used to
detect the cam position with the photo sensor, using the fan shaped
light blocking plate attached to the switching shaft. Printing with the
transfer belt lowered is called monochrome mode and color printing
is called color mode.

Expansion Paper Fee der

The optional expansion paper feeder can be installed at the lower
part of the main unit. Including the main unit, up to five layers of
cassettes can be used for cassette paper feeding.

1-16 Service Manual