Lexmark E310 Service Manual

Optra

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E310

4044-00X

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

4044-001

First Edition (March 1999)
The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties in certain transactions; therefore, this
statement may not apply to you.

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 to Lexmark International, Inc., Department
D22/035-3, 740 New Circle Road N.W., Lexington, Kentucky 40550, U.S.A. Lexmark may
use or distribute any of the information you supply in any way it believes appropriate
without incurring any obligation to you. 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 Optra are trademarks of Lexmark International, Inc., registered in the United
States and/or other countries.

Color Jetprinter is a trademark of Lexmark International, Inc.
Other trademarks are the property of their respective owners.

© Copyright Lexmark International, Inc. 1999.
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)(i i) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.

4044-001

Table of C ontent s

Notices and Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

Laser Notice
Safety Information

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

Options

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

Start

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

Service Error Codes
User Error Message Table
Power-On Self Test ( PO ST)
Symptom Tables

Service Checks

Cooling Fan Service Check
Cover Open Switch Service Check
Dead Machine Service Check
Fuser Service Check
Main Motor Service Check
Operator Panel Service Check
Operator Panel Button Service Check
Paper Feed Service Check
Print Quality Servi ce Check
Parallel Port Service Check

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

Memory Te s t
Diagnostic Test
Print Quality Test
User Mode Print Test
Configuration Mode
Hex Trace
Restoring Factory Defaults
Engine Clean Cycle
Toggle Demo/Normal Mode
Printer Operation
Paper Path

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

Handling ESD-S ensi tive Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

. . . . . . . . . . . . . . . . . . . . . . 2 -12

. . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -18

. . . . . . . . . . . . . . . . . . . . . . . . . . 2 -19

. . . . . . . . . . . . . . . . . . . . 2-20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -15

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

iii

4044-001

Removal Procedures

Screw Identification Table
Covers
Frame Assembly
Fuser Assembly
HVPS
Interconnect Board
Engine/L VPS Bo a r d
Main Driv e Ass e m b ly
Pick Roll Assembly
Printhead Assembly
Transfer Roll

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

Controller Board
Engine/L VPS Bo a r d
High Voltage Power Supply
Interconnect Board

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Assembly 1: Covers
Assembly 2: Frame
Assembly 3: Fuser
Assembly 4 : Main D riv e
Assembly 5: Paper Feed
Assembly 6: Electronics
Assembly 7: Options
Assembly 8: Miscellaneous

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21

iv Service Manual

4044-001

Notices and Safety Information

Laser Notice

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 825.

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 wav elength 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.

v

4044-001

Laser Advisory Label

vi

4044-001

Class 1 Laser Statement Label

vii

4044-001

Laser

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) 825 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.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante 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 825 relatives aux produits laser de Classe I.

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 .

viii

4044-001

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 825.

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

1..

Avisos sobre 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 825 para productos láser de
Clase I (1).

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 nanómetros. 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
la Clase I durante su uso normal, el mantenimiento realizado por el
usuario o cualquier otra situación de servicio técnico.

ix

4044-001

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os
requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a
Classe I (1) de produtos laser. Em outros locais, está certificada
como um produto laser da Classe I, em conformidade com os
requisitos da norma IEC 825.

Os produtos laser da Classe I não são considerados perigosos.
Internamente, a impressora contém um produto laser da Classe 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. Voor de Verenigde Staten zijn deze eisen
vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 825.

Laserprodukten 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 gebruik, bij onderhoud of
reparatie conform de voorschriften, nooit blootstelling mogelijk is
aan laserstraling boven een niveau zoals voorgeschreven is voor
klasse 1.

x

4044-001

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i
overenstemmelse med kravene i IEC 825.

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 bø lgelængdeområdet
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 servicebetingelser.

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS
21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I
laserlaitteiden IEC 825 -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.

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.

xi

4044-001

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 825.

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 milliwatt som arbetar i våglängdsområdet 770­795 nanometer. Lasersystemet och skrivaren är utf ormade så att det
aldrig finns risk för att någon 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-laserprodukt i samsvar med kravene i IEC

825.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren

inneholder internt en klasse IIIb (3b)-laser, som består av en
gallium-arsenlaserenhet 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
serviceoperasjoner.

xii

4044-001

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 825.

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 sistema làser i la impressora han sigut
concebuts de manera que mai hi hagi exposició a la radiació làser
per sobre 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.

xiii

4044-001

Japanese Laser Notice

Chinese Laser Notice

xiv

4044-001

Korean Laser Notice

Safety Information

•

This product is designed, tested and approved to meet strict
global safety standards with the use of specific Lexmark
components. The safety features of some parts may not
always be obvious. Lexmark is not responsible for the use of
other replacement parts.

•

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.

xv

4044-001

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.

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.

xvi

•

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.

4044-001

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

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.

xvii

4044-001

Informações de Segurança

•

Este produto foi concebido, testado e aprovado para
satisfazer os padrões globais de segurança na utilização de
componentes específicos da Lexmark. As funções de
segurança de alguns dos componentes podem não ser
sempre óbvias. A Lexmark não é responsáv el 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 f acto e tomar os
cuidados necessários.

Informació de Seguretat

•

Aquest producte està dissenyat, comprovat i aprovat per tal
d'acomplir les estrictes normes 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.

xviii

•

La informació pel manteniment d’aquest producte està
orientada exclusivament a prof essionals i no està destinada a
ningú que no ho sigui.

•

El risc de xoc elèctric i de danys personals pot augmentar
durant el procés de desmuntatge i de servei d’aquest
producte. El personal professional ha d’estar-ne assabentat i
prendre les mesures convenients.

4044-001

Chinese Safety Information

Korean Safety Information

xix

4044-001

xx

4044-001

1. General Information

This printer is a letter-quality laser page printer designed to attach to
an IBM Personal Computer or other computers compatible with the
IBM Personal Computer (with 386 processor or higher) and
Macintosh Computers via the USB connection.

The printer is capable of printing at speeds of 8 pages per minute
with a true 600 dpi resolution or 1200 dpi Image Quality resolution.
The base printer comes with 2MB of memory and is expandable to
66MB via the single DRAM SIMM slot. User flash memory is also
available in 1MB, 2MB and 4MB.

Options

The following options are available. Some options are not available
in every country. Contact your point of purchase f or options a v ailab le
in your country.

Memory options of 8MB, 16MB, 32MB and 64MB
Flash memory options of 1MB, 2MB and 4MB

General Information 1-1

4044-001

Acron yms

CSU Customer Setup
DRAM Dynamic Random Access Memor y
EP Electrophotographic Process
EPROM Erasable, Programmable Read-Only

Memory
ESD E lectrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LASER Light Amplification by Stimulated Emission

of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
MROM Masked Read Only Memory
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PC Photoconductor
POST Power-On Self Test
ROM Read O nly Memory
SIMM Single In-Line Memor y Module
SRAM S t atic Random Ac cess Memo ry
UPR Used Parts Return
USB Universal Serial Bus
V ac Volts alternating current
V dc Volts direct current

1-2 Service Manual

4044-001

2. Diagnostic Information

Start

CAUTION:
interlock switch and the printhead shutter actuator at the same

. To perform some of the service checks and tests, such as

time

troubleshooting paper feed problems, you need to actuate the top
cover interlock switch with the covers opened or removed and power
applied to the machine. It is important for personal safety that you

NEVER

DO NOT, FOR ANY REASON

when power is on.
Remove power from the printer before you connect or disconnect

any cable or electronic board or assembly for personal safety and to
prevent damage to the printer.

Use the service error code, user error message, symptom table,
service checks, and diagnostic aids in this chapter to determine the
corrective action necessary to repair a malfunctioning printer.

The lights on the operator panel can indicate either a user error
message or service error message. When a ser vice error occurs,
the printer stops printing and all operator panel LEDs blink in a
continuous pattern, indicating a serv ice error, until the printer is
powered off. If all operator panel LEDs are blinking, go to the

Error Codes” on page 2-2

When a user error message occurs, one or two operator panel LEDs
are on solid or blinking. Go to the

page 2-6

.

manually actuate or disable the top cover

, disable the printhead shutter actuator

“Service

.

“User Error Message Table” on

If your machine does not have a service error code and does not
complete POST, go to the
machine completes POST without an error, and you have a
symptom, go to the
your symptom and take the appropriate action.

If a service error code appears while you are working on the
machine, go to the
indicated action for that error.

“Service Error Codes” on page 2-2

“POST Symptom Table” on page 2-10

“Base Printer Symptom Table” on page 2-10

and take the

Diagnostic Information 2-1

. If your

. Locate

4044-001

Service Error Codes

Primary Servi c e Error Codes

When a service error occurs the printer stops printing and all
operator panel LEDs blink in a continuous pattern, indicating a
service error, until the printer is powered off.

Press and release the operator panel button to display the service
error code. Locate the blinking LEDs in the following table and take
the indicated action.

Blinking Operator Panel LED Action

Software Service Error Code Run the Printer Diagnostic Test to

diagnose between t he RO M SIMM
and the controller board. If no other
error code displays after the test
completes, replace the controll er
board.

Fuser F ailure Error Press and release the operator

panel button to view the secondary
service error code. Go to

“Secondary Service Error Codes” on
page 2-5.

Laser Diode Failure Inspect the printhead cable and

replace as necessary. Replace the
printhead assembly. If this does not
correct the problem, replace the
engine/LVPS board.

2-2 Service Manual

4044-001

Blinking Operator Panel LED Action

Mirror Motor Failure Inspect the printhead cable and

replace as necessary. Replace the
printhead assembly. If this does not
correct the problem, replace the
engine/LVPS board.

Optional Memory Error Replace the opt ional m emory SIMM.

If this does not corr ect the problem,
replace the controller board.

ROM Checksum Error Replace the ROM SI MM. If thi s does

not correct the problem, replace the
controller board.

Base Memory Error Replace the co ntr oller board

NVRAM Fai lure Error Replace the controller board

Diagnostic Information 2-3

4044-001

Blinking Operator Panel LED Action

ASIC Register Failure Error Replace the controller board

ASIC SRAM Failure Error Replace the controller board

Flash Memory Fail ure Error Replace the ROM SIMM w/Flash. If

this does not correct the problem,
replace the controller board.

Font Checksum F ai lure Error Replace the ROM SIMM. If t his does

not correct the problem, replace the
controller board.

Engine/LVPS Board
Communications Failure Error

Replace the engine/LVPS board

2-4 Service Manual

4044-001

Secondary Ser vice Er ror Codes

For some service error codes, a second service error code is used
to further describe the error. When a service error occurs, pressing
the operator panel button after viewing the primary service error
code displays the secondary ser vice error code. The following table
contains the secondary service error codes.

Blinking Operator Panel LED Action

Fuser Failure - Over Temperature Go to the “Hot Fuser Service Check ”

on page 2-18.

Fuser Failure - Under
Temperature

Fuser Failure - Thermistor Open Go to the “Fuser Service Check” on

Go to the “Cold Fuser Serv ice

Check” on page 2-15.

page 2-15.

Diagnostic Information 2-5

4044-001

User Error Message Table

Primary User Error Message Table

When a user error message occurs the printer stops printing and
one or two operator panel LEDs are on solid or blinking until the
printer is powered off. Locate the printer’s LED Status in the
following table and take the indicated action.

User Error Message LED Status Action

Paper Jam Paper Jam on solid Open cover and clear

Load Manual Paper/
Envelope

Load Paper/Load
Envelope

Load P aper bl inks and
Press Button on solid

Load Paper on solid
and Press Button on
solid

any paper jams. Close
the top cover. If the
error message is still
present, go to
the“Paper Feed

Service Check” on
page 2-20

Load media into the
manual slot and push
the operator pan el
button to resume
printing one sheet or
do an operator panel
reset by pressing and
holding the operator
panel button for more
than three seconds .

Load media in the
appropriate paper tr a y
and push the oper ato r
panel button to
resume printing or do
an operator panel
reset by pressing and
holding the operator
panel button for more
than three seconds .

.

Top Cover Open Error on solid Close the top cov er. If

the error LED remains
on solid and POST
does not continu e, go
to the

“Cove r Open
Switch Service
Check” on page 2-12

2-6 Service Manual

.

4044-001

User Error Messa ge LED Status Action

Memory Full/Complex
Page /Res oluti on
Reduction Warning/
Font Error/ Resource
Save Off Deficient
Memory

Flash Memory Full Error blinks and Press

Error on solid and
Press Button on solid

Button on solid

The printer memory is
full or the page is too
comple x to print. The
printer is forced to
reduce the resolution
of a formatte d page to
300 dpi before
printing, or the printer
is unable t o maintain
the required data
transfer rate. Go to the

“Secondary User
Error Message Table”
on page 2-8.

This condition only
occurs when the
Flash memory is full.

Diagnostic Information 2-7

4044-001

Secondary User Error Message Table

Press and release the operator panel button two times to displa y t he
user secondary error LED status. Each press and release action
must be performed within a half second. Locate the printer’s LED
status in the following table and take the indicated action.

User Error Message LED Status Action

Complex Page Ready, Error, and

Press Button on solid

Memory Full Ready, Data, Err o r,

and Press Button on
solid

Resolution Reduction Re ady, Data blinking

and the Error, Press
Button on solid

Switch the printing
mode to a differ ent
printing mode using
the Lexm ark dri ver for
Windows, or push the
operator panel button
to resume printing, or
do an operator panel
reset by pressing and
holding the operator
panel button for more
than three seconds .

Change the printing
mode to Quick Print
Plus or reduce the
comple xity of the job
or the resolution, or
push the operator
panel button to
resume printing, or do
an operator panel
reset by pressing and
holding the operator
panel button for more
than three seconds .

Switch from the GL/2
or raster mode to
Quick Print Plus mode
using the Lexmark
driver for Windows, or
press the operat or
panel button to
resume printing, or do
an operator panel
reset by pressing and
holding the operator
button for mo re th an
three seconds.

2-8 Service Manual

4044-001

User Error Messa ge LED Status Action

Font Error Data blinking and

Error , Press Button on
solid

Resource Save Off
Deficient Memory

Ready blinking and
Error , Press Button on
solid

The print command is
requesting a font that
is not present or
installed. The user
must select a di ff erent
font or t ry turning the
Best Fit set ting on and
retry the print
command.

The prin te r la cks
sufficient memory to
enable Resource
Save. It is
recommended that
the user insta ll
additional me mo ry or
set each link b uffer to
the Auto value.

Power-On Self Test (POST)

When you turn the printer On, it performs a Power-On Self Test.
Check for correct POST functioning of the base printer by observing
the following:

1. All LEDs turn on solid.

2. All LEDs turn off.

3. The cooling fan and fuser lamp turn on.

Note:

operating temperature. As the temperature drops, the lamp
turns back on automatically.

The fuser lamp turns off once the thermistor reaches

4. The LEDs begin to turn on then off sequentially.

5. Once the fuser has reached operating temperature, the main
motor turns on and the pick roller shaft assembly rotates to
home position.

6. The Ready LED turns on solid while the Data LED blinks.

7. The engine/LVPS board checks the status of the input and exit
paper feed sensors.

8. The main motor turns off.

9. The Data LED turns off.

Diagnostic Information 2-9

4044-001

Symptom Tables

POST Symptom Table

Symptom Action

The main motor, cooling fan and
fuser do not come on.

POST completes except one or
more LEDs do not come on.

None of the LEDs come on. Go to the “Operator Panel Service

Main motor does not come on. Go to the “Main Motor Service

Fan does not come on. Go to th e “Cooling Fan Service

Fuser lamp does not come on. Go to the “Col d Fuser Service

Fuser lamp ne ver turns off. Go to the “Ho t Fu ser S ervic e Che ck”

The paper feed picks and tries to
feed paper.

Go to “Cover Open Switch Service

Check” on page 2-12.

Go to the“Operator Panel Service

Check” on page 2-19.

Check” on page 2-19.

Check” on page 2-18.

Check” on page 2-12.

Check” on page 2-15.

on page 2-18.

Go to the “Paper Feed Service

Check” on page 2-20.

Base Printer Symptom Table

Symptom Action

Dead Machine (no power) Go to the “Dead Machine Service

Check” on page 2-13.

Fan noisy or not working Go to the “Cooling Fan Service

Check” on page 2-12.

Fuser parts melted Go to the “Ho t Fuse r Serv ice Chec k”

on page 2-18.

Fuser lamp doesn’t light Go to “Col d Fuser Service Check ” on

page 2-15.

Toner not fused to the paper Go to “Cold Fuser Service Check ” on

page 2-15.

2-10 Service Manual

4044-001

Symptom Action

Blank page Go to “Blank page” on page 2-23.
Black page Go to “Black page” on page 2-24.
Heavy bac kground Go to “Heavy background” on

page 2-25.

Light print Go to “Light print” on page 2-28.
White or black lines or bands Go to “White or bl ac k line s or bands”

on page 2-29.

Toner on back of page Go to “Toner on back of page” on

page 2-29.

Incorrect characters print Go to “In correct characte rs print” on

page 2-29.

Paper jams Go to “Paper Feed Service Check”

Main Motor noisy or does not
move

Paper never pi cks Go to “Paper never picks” on

Paper feeds continuously Go to “Paper picks during POST

Paper skew Go to “Paper Feed Service Check”

Printer not communicating with
host

Pape r wrinkled or bent G o to “Paper "trees", wrinkles,

Top cover will not close Go to “Cover Open Switch Service

Operator panel button does not
respond

Operator panel LEDs do not light
or very dim

on page 2-20.

Go to “Main Motor Service Check”

on page 2-18.

page 2-22.

and/or continuously” on page 2-21.

on page 2-20.

Go to “Parallel Port Service Check”

on page 2-30.

stacks poorl y or curl s” on page 2-23.

Check” on page 2-12.

Go to “Operator Panel Button

Service Check” on page 2-20.

Go to “Operator Panel Service

Check” on page 2-19.

Diagnostic Information 2-11

4044-001

Service Checks

Note:

All service checks which involve measuring voltages of the
circuit boards (except the controller board) must be performed with
the engine/LVPS to controller board cable disconnected and the
printer positioned on its left side. This provides the servicer access
to the various circuit boards underneath the printer while supplying
necessary power to the rest of the printer.

Cooling Fan Service Check

FRU Action

Interconnect Board
Cooling Fan

Make sure motor cable is properly
seated in location CN408 on the
interconnect board. Disconnect the
cable and check connector-pin
CN408-3 for +24 V dc. If the voltage
is not present, repl ace the
interconnect board. If the voltage is
present, replace the cooling fa n.

Cover Open Switch Service Check

Note:

all the way, engaging the cover open switch lever. The lever can
easily be positioned incorrectly if the top cover has been removed
and replaced.

Make sure a toner cartridge is installed and the cover closes

FRU Action

Cover Ope n Swit ch Make sure the cover open switch

cable is properly seated in CN2 of
the HVPS. Disconnect the cable and
check the switch for continuity. Push
the cover open switch lever down to
engage the sw it ch and close the
circuit. If the circuit does not close,
replace the switch.

2-12 Service Manual

4044-001

FRU Action

HVPS
Engine/LVPS Board

Measure the voltage at CN2-3 of the
HVPS. It measures +24 V dc. If
voltage is present at CN2-3, check
for continuity between CN2-1 and
CN1-2. If continuity does not exist,
replace the HVPS. If continuity does
exist, check the HVPS to engine/
LVPS board cable for continuity.
Replace if defective. If voltage is not
present at CN2-3, check the voltage
at CN1-1. It measures +24 V dc. If it
does, repl ace the HVPS. If it does
not, check t he voltage at CN2-2 of
the engine/LVPS board. It measures
+24 V dc. If it does, replace the
HVPS to engine/LVPS board cable.

Dead Machine Service Che c k

Note:

following limit s :
100 V ac - 127 V ac for the low voltage model printer
200 V ac - 240 V ac for the high voltage model printer

Check the AC line voltage. The voltage should be within the

FRU Action

LVPS Fuse Check the fuse on the LVPS for

continuity. Replace with the
appropriate fuse if blown. If a fuse
blow s again after being replaced,
install a new fuse and go to “Engine/

LVPS Board” on page5-4 and check

the engine/LVPS board output.

Diagnostic Information 2-13

4044-001

FRU Action

Engine/LVPS Board
Power Switch

LVPS to Interconnect Board Cable Check the conti nuity of the LVPS to

Interconnect Board Reconnect the LVPS to the

Disconnect t he cab l es fr om CN2 and
CN5 and leave the cabl es connect ed
to the power switch attached. With
the printer positioned on its left side
and the engine/LVPS board
positioned on a flat surface, turn the
power switch on and check the AC
line voltage at connector CN201. If
no voltage is present, replace the
power switch. If line vo lt age is
present, measure t he voltages at
connectors CN2 and CN5. Go to
the“Engin e/LVPS Board” on

page 5-4 and check for correct

voltage measurements. Replace the
engine/LVPS board if any of the
voltage measurements are incorrect.

interconnect board cable. Replace
the cable if it does not measure
continuity.

interconnect board cable. Go to

“Interconnect Board” on page 5-12

and measure voltages on the
following connectors on the
interconnect board:

2-14 Service Manual

CN401/CN402/CN403/CN404/
CN405/CN407/CN408

If any of the measur ed voltages are
incorrect, replace the interconnect
board.

4044-001

Fuser Service Check

Cold Fuser Service Check

When toner is partially fused to the paper, it is usually caused by low
fuser temperature.

Avoid handling the lamp as much as possible as it is easily broken.
Be careful not to touch the glass housing with bare hands as skin
contains acids that can weaken the glass.

The line voltage to the printer must be within the following limits:
100 V ac - 127 V ac for the low voltage model printer
200 V ac - 240 V ac for the high voltage model printer
Turn the printer off and wait a few minutes for the fuser lamp to cool.

Turn the machine on and observe the lamp turning on during POST.
You can see the lamp with the left side cover and fuser wire cover
removed.

Diagnostic Information 2-15

4044-001

The fuser lamp does light

FRU Action

Thermistor If the fuser lamp comes on and a

Fuser Lamp Make sure the correct voltage lamp

fuser f ailure LED err or code disp lays ,
be sure the thermistor is cont acting
the hot roll and the thermistor cable
is firmly seated in connector CN1 on
the LVPS board. Check f or ex cessiv e
toner buildup on the surface of the
thermistor. Clean or replace as
necessary. Turn the printer off and
disconnect the thermistor cable from
CN1 on the LVPS board. Meas ure
the resistance of the thermistor
between CN-1 and
CN-2. The resistance measures
approximately 225K ohms when
cool. Replace the thermistor as
necessary.

is installed. The voltage rating is
stamped on one of the lamp
contacts.

2-16 Service Manual

4044-001

The fuser lamp does not light

FRU Action

Fuser Lamp
Lamp Cable
Thermistor
LVPS

Tur n the printer off and disconnect
the fuser lamp wires fr om the f user.
Check for cont inuity acros s the fuser
lamp wire contacts. If there is
continuity, go to step 1: Continuity.
If there is no conti nuity, go to
step 2: No Continuity.

Step 1: Continuit y
Measure the voltage at connector

CN202 on the LVPS. It should match
the line v oltage. If it does not,
replace the LVPS. If line voltage is
present, check the fuser lamp cable
for continuity. Replace if
def ective.Make sure the fuser
thermistor is correctly connected to
CN1 on the LVPS. If the problem
persists, disconnect the thermistor
cable from CN1 on the LVPS board
and measure the voltage between
CN1-1 and ground. The v oltage
measures approximately 3.9 V dc. If
the voltage is incorrect, re place the
LVPS. If correct, replace the
thermistor.

Step 2: No Continuit y
Check the t hermal fuse f or conti nuity.

If incor rect, repl ace the th ermal fuse .
If correct, replace the lamp.

Diagnostic Information 2-17

4044-001

Hot Fuser Service Check

FRU Action

Fuser Thermistor Disconnect the thermistor cable from

Fuser Lamp Make sure the correct voltage fuser

the LVPS. Measure the resistance
across CN1-1 and CN1-2 of the
thermistor cable. Replace the
thermistor if the resistance is lower
than 1k ohm or shorted.

lamp is installed. Replace if
necessary.

Main Motor Service Check

FRU Action

Interconnect Board
Main Motor
Main Motor Cable

Check the interconnect board f or the
following volt ages:

CN405-3 +24 V dc
CN405-4 +24 V dc

If these voltages are not correct,
replace the interconnect board. If
these volt ages are correc t, check the
main mo to r c abl e for con ti nu it y. If
continuity exists on each wire,
replace the main motor. If co nti nuity
does not exist on one or more of the
wires, replace the cable.

2-18 Service Manual

4044-001

Operator Panel Service Check

Inspect the operator panel cable for damage. Make sure the cabl e is
plugged in securely.

Run POST and check each LED for proper operation.

FRU Action

Operator Panel
Operator Panel Cable

Operator Panel
Operator Panel Cable
Controller Board

If more than one LED does not turn
on or an individual LED st ays on
solid during POST, check the
operator panel cable f or continuity.
Replace if defective. If the cable
measures continuity, replace the
operator panel.

If all LEDs are dim and operate
erratical ly during POST or all LEDs
come on and stay on solid during
POST, replace the following FRUs
one at a time in the order shown:

Controller Boar d
Operator Panel
Operator Panel Cable

If none of the LEDs come on, make
sure the cable is properly connected
to the operato r panel and the
controller board. Disconnect the
cable and check it for continuity.
Replace if necessary . If the cable
measures continuity, meas ure the
foll owing volt ages with the printer o n
at id le :

U5-1: Ground
U5-2: +5 V dc
U5-3: +5 V dc
U5-5: +5 V dc
U5-6: Ground

If these voltages are not correct,
replace the controller board. If these
voltages are correct, replace the
operator panel.

Diagnostic Information 2-19

4044-001

Operator Panel Button Service Check

FRU Action

Operator Panel
Operator Panel Cable

Disconnect the operator panel from
the operator panel cable. Check the
continuity between U5-1 and U5-2
on the operator pane l as you press
the operator pan el button. As the
button is pre ssed, continuit y is
present. Replace the operator panel
if continuity is not present. If
continuity is present, replace the
operator panel cable.

Paper Feed Service Check

Paper Jam error indication during POST

FRU Action

Exit Sensor Flag If the exit sensor flag is not resting

within the paper exit sensor during
POST, the printer displays a paper
jam message. Make sure the flag is
operating freely and correctly
installed.

Input Paper Feed Sensor Make sure the input paperfeed

sensor is working properly. A stuck
or incorrectly installed sensor
causes this error.

2-20 Service Manual

4044-001

Paper picks during POST and/or continuously

FRU Action

Pick Roller Clutc h
Solenoid

Check the pick roller clutch for wear.
The solenoid interacts with the
clutch controlling motion of the pick
roller. If the cam surface of the pic k
roller clutch assembly is worn, the
solenoid may not stop the pick roller
from rotat ing. Replace the pick roller
clutch assembly if necessary. Make
sure the spring on the solenoid is
properly installed. If the spring is
improperly instal led or missing, the
pick roller will continuously pick
paper.

Paper picks but stops about an inch down th e pa g e

FRU Action

Roller Guides Check for correct position of roller

guides on pick roller assembly.

Paper picks but stops half way through the printer

FRU Action

Input Paper Feed Sensor
Interconnec t Board

Make sure the input paper feed
sensor is w orking properly. Check for
a broken or stuck flag on the input
paper feed sensor. Check to make
sure the cable is seated on the
CN401 connector on the
interconnec t board. Disconnect the
cable and check for the following
voltages:

CN401-3 +5 V dc
CN401-4 Ground

If these voltages are not correct,
replace the interconnect board. If
correct, replace the input paper feed
sensor.

Diagnostic Information 2-21

4044-001

Paper never picks

FRU Action

Paper Tray Make sure the paper tray is correctly

Pick Roller Solenoid Make sure solenoid is installed

installed. The black mylar guide
sheet in the front of the tray must be
positioned in the paper path just
behind the pic k roller assembly. This
guide sheet can easily block th e
paper path if installed incorrectly.

correctly an d its cable i s plugged int o
CN402 on the interconnect board. If
installation is correc t, disconnect t he
solenoid and check CN402-1 for
+24 V dc. If the voltage is present,
replace the solenoi d. If the v ol tage is
not present , rep lace t he inte rconnect
board.

Paper occasionally picks or picks multiple sheets at once

FRU Action

Pick Roller Assembly Check pick roller assem bly for wear.

Replace as necessary.

Paper Separator Assembly Check the friction pad on the paper

separator for signs of wear. Replace
as necessary.

Pick Roller Pad Assembly Check the friction pad on the pick

roller pad assembly for signs of
wear . Replace as necessary.

2-22 Service Manual

4044-001

Paper "trees", wrinkles, stacks poorly or curls

FRU Action

Transfer Roller This problem is most likely due to a

worn transfer roller. A worn transfer
roller causes the printer to run hotter
than required for the media being
printed. Excessive heat can cause
paper treeing problems, poor
stacking or cu rl.

Print Quality Service Check

Blank page

FRU Action

Toner Cartridge Remove the toner cartridge and

gently shake the assembly to evenly
distribute the toner.

Printhead
Printhead Cable
HVPS
Engine/LVPS Board

Blank pages can be caused by a
defective printhead assembly, high
voltage power supply or engine/
LVPS board. Disconnect the
printhead cable from the HVPS and
measure the signals on connectors
CN3 and CN4. Go to the “ High

Voltage Power Supp ly ” on page5-9

in the connector locations chapter
and check the voltage
measurements. If the voltages are
correct, ch eck the printhead cable
for continuity. If the cable measures
continuity, replace the printhead. If
the cable does not measure
continuity, replace the cable. If the
voltage measurements are not
correct, replace the HVPS. If the
problem still exists, replace the
engine/LVPS board.

Diagnostic Information 2-23

4044-001

Black page

Note:

Incorrect laser exposure or incorrect charging of the
photoconductor causes an all black page.

FRU Action

HVPS Contacts Check the contacts f or

contamination and correct
installation. Replace as necessary.

Engine/LVPS Board
HVPS Cable
HVPS

Make sure the HVPS to engine/
LVPS cable is correctly installed.
Disconnect the cable and measure
the signals on CN2 of the engine/
LVPS board. Go to “Engine/LVPS

Board” on page 5-4 and check the

voltage measurements. If th e
voltages are not correct, repla ce the
engine/LVPS board. If the voltages
are correct, check the HVPS to
engine/LVPS cable for continuity. If
the cable does not measure
continuity, replace the cable. If the
cable measures continuity, replace
the HVPS.

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Heavy background

Poor de v elopment or poorly charged toner particles cause excessive
background. This is more noticeable as the toner cartridge nears
end of life.

FRU Action

Toner Cartridge Make sure toner cartridge is

correctl y installed and the high
voltage contacts are clean. If the
cartridge is installed cor rectly, try a
new cartridg e.

HVPS Contacts
HVPS Board
Engine/LVPS Board

Check th e cont acts for corre ct
installati on and contaminat ion where
contact is made with the toner
cartridge and HVPS Board. Clean as
necessary. If this does not correct
the problem, replace the following
FRUs one at a time in the order
shown:

HVPS Board
Engine/LVPS Board

Diagnostic Information 2-25

4044-001

Partial blank image/white spots (no periodic pattern )

FRU Action

Toner Cartridge Remove the toner cartridge and

Fuser Backup Roller Springs Check left and right backup rol ler

Paper Make sure recommended paper is

gently shake the assembly to evenly
distribute the toner. If toner cartridge
is low, try a new one.

springs and backup roller to ensure
adequate ev en pre ssure is appl ied to
the fuser hotroll.

being used.

Variation in image density horizontally across page

FRU Action

Toner Cartridge The charge rol l in th e toner cartridge

may have an unbalanced pressure
against the PC drum. Try a new
toner cartridge.

Transfer Roll er Beari ng Assembly
Transfer Roll er

Check the springs in the l eft and
right transfer roller bearings . The
bearing assemblies should support
the transfer roller, applying even
pressure to the PC drum. Replace
either or both transfer roller bearing
assemblies i f the spri ngs sho w sign s
of damage or fati gue. Inspect the
transfer roller for signs of wear or
damage and replace as necessary.

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Periodic irregularity down page

FRU Action

PC Drum (Toner Cartridge)
Distance Between Irregularity

96.2 mm
Charge Roller (Toner Cartridge)
Distance Between Irregularity

37.7 mm
Supply Roller (Toner Cartridge)
Distance Between Irregularity

31.3 mm
Dev eloper Roller

(Toner Cartridge)
Distance Between Irregularity

46.1 mm
Transfer Roller
Distance Between Irregularity

47.1 mm
Hot Roll
Distance Between Irregularity

56.4 mm

The PC drum or gear driving the PC
drum may be contami nated or
damaged. Inform the customer to
replace the toner cartridge.

The charge roller or gear driving the
charge roll er may be contaminated
or damaged. Inform the customer to
replace the toner cartridge.

The supply roller or gear driving the
supply rol ler may be contaminat ed or
damaged. Inform the customer to
replace the toner cartridge.

The supply roller or gear driving the
develope r roll e r m ay be
contaminated or damaged. Inform
the customer to re place the toner
cartridge.

The transfer roller or gear driving t he
transfer roller may contaminated or
damaged. Inspect the roller and
gear. Replace as necessa ry.

The hot roll of the fus er or gear
driving the hot roll m ay be
contaminated or damaged. Inspect
the hot roll and gear. Replace or

clean as necessary.
Backup Roller
Distance Between Irregularity

56.5 mm

The backup roller of the fuser may

be contaminated or damaged.

Inspect and replace as necessary.

Diagnostic Information 2-27

4044-001

Poor fusing of image

FRU Action

Fuser Lamp The fuser ma y not be oper ating at

Paper Make sure recommended paper is

the proper temperature to fuse the
toner to the paper. Go to the “Cold

Fuser Service Check” on page 2-15.

being used.

Light print

FRU Action

Toner Cartridge Make sure the toner cartridge is

Transfer Roll er
HVPS Contact (Transfer Roller)
HVPS Board

installed correctly and is not low on
toner. If the problem continues,
install a new toner cartridge.

Check the transfer roller for signs of
toner buil dup and contamination.
Inspect the HVPS contact (transfe r
roller) for contaminati on. I nspect the
HVPS board for contamination
where it meets the HVPS co ntacts . I f
all components appear free of
contaminatio n, replace the following
FRUs one at a time in the order
shown:

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Transfer Roll er
HVPS Contact (Transfer Roller)
HVPS Board

4044-001

White or black lines or bands

FRU Action

Toner Cartridge
Paper Feed Drive Gears

Banding appears as l ight or dark

horizontal li nes on a uniformly gray

page or on a page with a large area

of graphic s. Bandi ng is primarily due

to a variation in the speed of the

paper as it feeds through the printer

especiall y in t he develo per and

transfer process. Inspect the toner

cartridge and paper feed

components, especially the drive

gears, for signs of wear, debris,

binds or damage.

Toner on back of page

FRU Action

Print Cartridge Inspect the overall paper path for

signs of spilled toner. Gently clean

the contaminat ed areas with a soft

cloth or compressed air.
Fuser Hot Roll

Backup Roller

The fuser hot roll can caus e to ner on

the back of the paper if toner is

buildi ng up on the hot roll. This

buildup may transfer to the backup

roller, later tr ansferring to the

backside of the paper. Inspect the

hot roll an d backup roller for si gns of

contaminati on and replace as

necessary.
Transfer Roller A transfer rol ler contaminated with

toner can cause toner to transfer to

backside of printed pages. Ins pect

the transfer roller for contaminat ion

and replace as necessary.

Incorrect characters print

Make sure the correct printer driver software is installed. Incorrect
software can cause incorrect characters to print and the image may
not fit the page.

Diagnostic Information 2-29

4044-001

Parallel Port Service Check

1. Perform a print test to make sure the printer prints correctly.

2. Be sure the printer cable is designed for bidirectional printing.

3. Be sure the user application is set up correctly. Improper set up
can prevent establishing a communication link with the printer.

4. Try enabling the parallel port pull-up resistors. Go to

Mode 1” on page 3-8

resistors. If the printer still does not print, disable the resistors.

5. If the internal print test page prints correctly, the user
application/printer driver is set up correctly and the correct bi­directional parallel cable is installed, yet the printer still fails to
print on command from the host, replace the controller board.

. Tr y pri nting a test page after enabling

“Parallel

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3. Diagnostic Aids

This chapter explains the tests and procedures you can run to
identify printer failures and verify that repairs have corrected the
problem.

Memory Test

The following tests run sequentially when performing this test:

Standard Memor y Test
Optional Memory Test

The memor y test runs automat ically dur ing POST if a different size
optional memory SIMM is installed since the last printer power on.

Perform the following steps to run the Memory Test:

1. Turn the printer off.

2. Open the top cover.

3. Press and hold the operator panel button as you turn on the
printer. Release the button once the Error LED comes on solid.

4. Close the top cover.

5. If all the diagnostic tests run correctly, the Data LED blinks. If a
test fails, the Error LED pattern for the service error code dis­plays on the operator panel. Go to the “Service Error Codes” on

page 2-2 and t ake the indicated action for that error.

Diagnostic Test

Once the memory test is complete, the diagnostic test pages can be
printed by briefly pressing the operator panel button. Two pages are
printed. The first page is a listing of various printer settings and code
level. The second page is used to inspect registration. If the printer
requires a registration adjustment, you must contact your next level
of suppor t to obtain the software utility that enables you to adjust
registration.

Diagnostic Aids 3-1

4044-001

Print Quality Test

There are three print quality test pages. The first page displays the
installed printer base code level and user default settings for the
following:

Top Margin Offset
Left M a r g in Off s e t
Printer Page Count
Instal led Memory
PQET Setting (on/off)
Toner Saver (on/off)
Print Resolution
Print Darkness

The next two test pages are used to evaluate print quality. One test
page is gray and the other is black. Perform the following steps to
print the second test page:

1. Turn the printer off.

2. Open the top cover.

3. Turn the printer power on.

4. When the Error LED comes on solid, double-click the operator
panel button.

5. Once the Error and Press Button LEDs start blinking, close the
top cover.

6. The Ready LED comes on solid and the Error and Press Button
LED continue blinking.

7. Double-click the operator button four times. The Ready and
Data LEDs come on solid while the Error and Press Button
LEDs continue blinking.

8. Perform a long button press until all LEDs come on solid.

9. The test pages are printing.

10. When the test pages have finished printing, the Ready LED
comes on solid and the Data LED goes off.

Note: After the print quality test pages print, the printer automati­cally returns to the Ready mode.

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4044-001

User Mode Print Test

The User Mode Print Test Page displays the user default values,
installed options, printer features, various typefaces, and the
installed printer base code level.

1. Turn the printer power on. The Ready LED comes on solid
(printer is in the ready state).

2. Press and release the operator panel button.

3. The Ready LED comes on solid and the Data LED blinks indi­cating the printer is busy.

4. The test page prints and the operator panel Ready LED comes
on solid and the Data LED turns off.

5. The printer returns to the Ready mode.

Configur ation Mode

The configuration mode gives the ability to set the following printer
functions through the operator panel:

Parallel Port Sett ing s

Enable Port
NPA Mode
Protocol
Mode 1
Mode 2
Strobe Adjust

USB Settings

Enable Port
NPA Mode

PPDS Activated
Auto CRLF/LFCR

Diagnostic Aids 3-3

4044-001

Operator Panel Configuration Mode Button Definition

Term Description Result

Brief Button Press Press the operator

panel but ton n o longer
than three seconds.

Long Button Press Press and hold the

operator panel button
for more than three
seconds.

Double-Click Button
Press

Press and release the
operator panel button
two times. Each press
and release action
must be performed
within a half second.

This action moves
through the configura­tion mode settings.

This action selects
and sav es the setting
for the menu item dis­played. To indicate
that the setting i s
saved, all LEDs blink
once.

This action moves
through the configura­tion mode menu.

Perform the following steps to enter the configuration mode:

1. Turn the printer power off.

2. Open the top cover.

3. Turn the printer power on.

4. When the Error LED comes on solid, double-click the operator
panel button.

5. When the Error and Press Button LEDs start blinking, close the
top cover. The Ready LED comes on solid and the Error and
Press Button LEDs continue blinking.

6. Double-click the operator panel button two times. The Load
Paper LED comes on solid while the Error and Press Button
LEDs continue blinking.

7. Perform a long button press. All LEDs blink once. The Ready
LED stays on solid. The printer is in the configuration mode.

8. To exit the configuration mode, turn the printer power off.

Configuration Mode Operator Panel Overlays

When in configuration mode, the first menu item and its setting are
displayed. The first menu i tem i s t he Parallel Port and is indicated by

3-4 Service Manual

4044-001

the solid Ready LED. The setting of the menu item is indicated by
the status of the Press Button LED. To change the menu item
setting, briefly press the operator panel button. Once the setting you
want is indicated by the status of the Press Button LED, perform a
long button press to save the setting. All LEDs come on while the
setting is saved. To select other menu items, double-click the
operator panel button until the menu item LED you want is selected.

There are ten menu items that can be selected by using the five
LEDs as indicated by the following overlays on two passes through
the configuration menu. The first time through the menu the LED
selected is on solid. The second time through the menu the LED
selected is blinking.

First pass - LED on solid overlay.

Parallel Port
Parallel NPA
Parallel Protocol
PPDS
CRLF/LFCR
Off/On/Auto

Second pass - LED blinking overlay

Operator Panel Button

Parallel Mode 1
Parallel Mode 2
Parallel Strobe
USB Port
USB NPA
Off/On/Auto

Operator Panel Button

Diagnostic Aids 3-5

4044-001

Configuration Mode Settings

The following is a description of the available configuration mode
menu items and settings. The asterisk (*) indicates the factory
default setting.

Par al le l Port

Parallel Port allows the user to enable or disable the parallel port. If
the port is not being used, disabling it frees allocated memory to be
used to process print jobs.

Perform the following steps to change the Parallel Port setting:

1. Enter the configuration mode.

Note:

current Parallel Port setting is indicated by the Off/On/Auto
(Press Button) LED. When the LED is off, the parallel port is
disabled. When the LED is *blinking, the parallel port is enabled.

2. Perform a brief button press to select the Parallel Port setting.

3. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

4. Exit the configuration mode by turning the printer power off.

The Parallel Port (Ready) LED comes on solid. The

Par al le l NPA

Parallel NPA mode allows two way communication between the host
and the printer.

Perform the following steps to change the Parallel NPA setting:

1. Enter the configuration mode.

2. Perform a double click button press. This moves to the Parallel
NPA item on the configuration menu. The Parallel NPA (Data)
LED comes on solid.

3. The current Parallel NPA setting is indicated by the Off/On/Auto
(Press Button) LED.

•

When the LED is on solid, all data received by the printer
must be in NPA packets. Any non-packet data is rejected as
bad packets.

•

When the LED is off, the printer is not performing any NPA
processing.

3-6 Service Manual

4044-001

•

When the LED is *blinking, the printer examines incoming
data and decides whether it is receiving NPA packets.

4. Perform a brief button press to select the Parallel NPA setting.

5. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

6. Exit the configuration mode by turning the printer power off.

Paralle l Pr o t oc ol

The printer supports two parallel protocol settings: standard and
fastbytes. When the protocol is set to standard, information is
received at a normal transmission rate. When the protocol is set to
fastbytes, information can be received at a much faster transmission
rate provided the host computer supports the fastbytes mode.

Perform the following steps to change the Parallel Protocol setting:

1. Enter the configuration mode.

2. Perform a double click button press twice. This moves to the
Parallel Protocol item on the configuration menu. The Parallel
Protocol (Load Paper) LED comes on solid.

3. The current Parallel Protocol setting is indicated by the Off/On/
Auto (Press Button) LED. When the LED is off, the Parallel
Protocol is set to standard. When the LED is *on, the Parallel
Protocol is set to fastbytes. Perform a brief button press to
select the Parallel Protocol setting.

4. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

5. Exit the configuration mode by turning the printer power off.

PPDS

To access the PPDS data stream, the PPDS setting must be set to
active. When PPDS is activated, the default Printer Language is
changed to PPDS and the default PCL and PostScript Smartswitch
settings are changed to Off.

Perform the following steps to change the PPDS setting:

1. Enter the configuration mode.

2. Perf orm a double click button press three times. This moves to
the PPDS item on the configuration menu. The PPDS (Paper
Jam) LED comes on solid.

Diagnostic Aids 3-7

4044-001

3. The current PPDS setting is indicated by the Off/On/Auto (Press
Button) LED. When the LED is *off, the PPDS is set to inactive.
When the LED is on, the PPDS is set to active. Perform a brief
button press to select the PPDS setting.

4. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

5. Exit the configuration mode by turning the printer power off.

CRLF/LFCR

This function controls whether or not the printer automatically
performs a carriage return after a line feed control command and
whether or not the printer automatically performs a line feed after a
carriage return control command.

Perform the following steps to change the CRLF/LFCR setting:

1. Enter the configuration mode.

2. Perform a double click button press four times. This moves to
the CRLF/LFCR item on the configuration menu. The CRLF/
LFCR (Error) LED comes on solid.

3. The current CRLF/LFCR setting is indicated by the Off/On/Auto
(Press Button) LED.

•

When the LED is *off, Auto CR after LF is off and Auto LF
after CR is off.

•

When the LED is on, Auto CR after LF is on and Auto LF
after CR is off.

•

When the LED is blinking, Auto CR after LF is off and Auto
LF after CR is on.

4. Perform a brief button press to select the CRLF/LFCR setting.

5. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

6. Exit the configuration mode by turning the printer power off.

Parallel Mode 1

Parallel Mode 1 controls whether or not resistors are enabled on the
parallel post signals. The default is to not have the resistors enabled,
however, this function is useful because some IBM clone PC’s have
open collector outputs on their parallel port signals.

3-8 Service Manual

4044-001

Perform the following steps to change the Parallel Mode 1 setting:

1. Enter the configuration mode.

2. Perf orm a double click button press fiv e times. This mov es to the
Parallel Mode 1 item on the configuration menu. The Parallel
Mode 1 (Ready) LED is blinking.

3. The current Parallel Mode 1 setting is indicated by the Off/On/
Auto (Press Button) LED. When the LED is off, the Parallel
Mode 1 is set to off. When the LED is *on, the Parallel Mode 1 is
set t o on. Pe rform a brie f bu t ton press to sel ect the Parallel
Mode 1 setting.

4. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

5. Exit the configuration mode by turning the printer power off.

Parallel Mode 2

Parallel Mode 2 controls whether or not the parallel port data is
sampled on the leading or trailing edge of strobe. The default is to
sample on the leading edge of strobe, however, some IBM clone
PC’s assumes that a printer will sample on the trailing edge.

Perform the following steps to change the Parallel Mode 2 setting:

1. Enter the configuration mode.

2. Perf orm a double clic k button press six times. This moves t o the
Parallel Mode 2 item on the configuration menu. The Parallel
Mode 2 (Data) LED is blinking.

3. The current Parallel Mode 2 setting is indicated by the Off/On/
Auto (Press Button) LED. When the LED is off, the Parallel
Mode 2 is set to sample on trailing edge. When the LED is *on,
the Parallel Mode 2 is set to sample on leading edge. Perform a
brief button press to select the Parallel Mode 2 setting.

4. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

5. Exit the configuration mode by turning the printer power off.

Paralle l Strobe

This setting allows the user to adjust the factory setting for the
amount of time strobe is sampled to determine that valid data is

Diagnostic Aids 3-9

4044-001

available on the parallel port. Each increment of the strobe adjust
value means the strobe is sampled 50ns longer.

Perform the following steps to change the Parallel Strobe Adjust:

1. Enter the configuration mode.

2. Perform a double click button press seven times. This moves to
the Parallel Strobe item on the configuration menu. The Parallel
Strobe (Load Paper) LED is blinking.

3. The current Parallel Strobe setting is indicated by the Off/On/
Auto (Press Button) LED. When the LED is *off, the Parallel
Strobe is set to normal. When the LED is on, the Parallel Strobe
is set to +1. When the LED is blinking, the Parallel Strobe is set
to +2. Perform a brief button press to select the Parallel Strobe
setting.

4. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

5. Exit the configuration mode by turning the printer power off.

USB Port

This menu item allows the user to enable or disable the USB port. If
the port is not being used, disabling it frees allocated memory to be
used to process print jobs.

Perform the following steps to change the USB Port setting:

1. Enter the configuration mode.

2. Perform a double click button press eight times. This moves to
the USB Port item on the configuration menu. The USB Port
(Paper Jam) LED is blinking.

3. The current USB Port setting is indicated by the Off/On/Auto
(Press Button) LED. When the LED is off, the USB Port is
disabled. When the LED is *blinking, the USB Port is enabled.
Perform a brief button press to select a different USB Port
setting.

4. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

5. Exit the configuration mode by turning the printer power off.

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4044-001

USB NPA

USB NPA mode allows for two wa y communication between the host
and the printer.

Perform the following steps to change the USB NPA setting:

1. Enter the configuration mode.

2. Perform a double click button press nine times. This moves to
the USB NPA mode item on the configuration menu. The USB
NPA (Error) LED is blinking.

3. The current USB NPA setting is indicated by the Off/On/Auto
(Press Button) LED.

•

When the LED is off, the USB port does not search for NPA
data within the received data.

•

When the LED is *blinking, the USB port searches for
optional NPA data within the received data.

•

When the LED is on solid, the USB port requires that data
sent to the printer be in NPA format.

4. Perf orm a brief button press to select a different USB NPA
setting.

5. Perform a long button press. All LEDs blink once, indicating the
setting is saved.

6. Exit the configuration mode by turning the printer power off.

Hex Trace

When the printer is in Hex Trace, it prints a hexadecimal and a
character representation of a print job. The printer does not
recognize any print controls or commands in this mode. A Hex Trace
printout is used to help isolate the cause of print problems.

When a job is printed, the printer operator panel displays the Hex
Tra ce indication, (Ready LED blinking), showing that the printer
remains in the Hex Trace mode. Turn the printer power off or do an
operator panel reset (long button press) to exit the Hex Trace mode.

Perform the following steps to enter the Hex Trace mode:

1. Turn the printer power off.

2. Open the top cover.

3. Turn the printer power on.

Diagnostic Aids 3-11

4044-001

4. When the Error LED comes on solid, double-click the opera­tor panel button.

5. Once the Error and Press Butt on LEDs start to blin k, cl os e
the top cover.

6. The Ready LED comes on solid and the Error and Press
Button LEDs continue blinking.

7. Double-click the operator button three times. The Paper J am
LED comes on solid while the Error and Press Button LEDs
continue blinking.

8. Perform a long button press until all LEDs come on solid.
The printer is in Hex Trace mode

9. To exit the Hex Trace mode, turn the printer power off.

Restoring Factory Defaults

Restoring factory defaults returns the printer settings to the original
factory settings.

Perform the following steps to invoke factory defaults:

1. Turn the printer power off.

2. Open the top cover.

3. Tur n the printer power on.

4. When the Error LED comes on solid, double-click the opera­tor panel button.

5. Once the Error and Press Button LEDs start blinking, close
the top cover.

6. The Ready LED comes on solid and the Error and Press
Button LEDs continue blinking.

7. Double-click the operator button one time. The Data LED
comes on solid while the Error and Press Button LEDs con­tinue blinking.

8. Perform a long button press until all LEDs come on solid.

9. The printer is reset to factory defaults.

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Engine Clean Cycle

The Engine Clean Cycle function prints one blank page in a special
cleaning mode. The cleaning mode helps eliminate small specs of
toner present in the background when printing.

Perform the following steps to perform the Engine Clean Cycle:

1. Turn the printer power off.

2. Open the top cover.

3. Turn the printer power on.

4. When the Error LED comes on solid, double-click the operator
panel button.

5. Once the Error and Press Button LEDs start blinking, close the
top cover.

6. The Ready LED comes on solid and the Error and Press Button
LEDs continue blinking.

7. Perform a long button press until all LEDs come on solid.

8. The printer feeds one page from the automatic paper feed slot
and then returns to normal printing mode.

Diagnostic Aids 3-13

4044-001

Toggle Demo/Normal Mode

The Toggl e Demo/N ormal Mode function enables or disables the
printer’s retail demo mode. When the printer is in Demo mode, demo
pages can be printed by briefly pressing the operator panel button.

Perform the following steps to enter Toggle Demo/Normal Mode:

1. Turn the printer power off.

2. Open the top cover.

3. Turn the printer power on.

4. When the Error LED comes on solid, double-click the operator
panel button.

5. Once the Error and Press Button LEDs start blinking, close the
top cover.

6. The Ready LED comes on solid and the Error and Press Button
LEDs continue blinking.

7. Double-click the operator button five times. The Ready and
Load Paper LEDs come on solid while the Error and Press
Button LEDs continue blinking.

8. Perform a long button press until all LEDs come on solid. The
printer is in Demo mode.

9. To retu rn the printer to Normal mode, repeat steps 1 through 8.

Printer Operation

Paper is held in a 150 page tray where it is picked by a center-fed
"D" shape pick roller. The paper follows an "L" shape path as it
moves through the printer. Images are created with toner on an OPC
drum within the toner cartridge. A transfer roller then draws the toner
off the OPC drum onto the paper. Once the toner is affixed to the
paper by the fuser, the paper exits either the top or front of the
printer.

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Paper Path

Diagnostic Aids 3-15

4044-001

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4044-001

4. Repair Information

CAUTION:

Read the following before handling electronic parts.

Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to
electrostatic discharge (ESD). To prevent damage to ESD-sensitive
parts, follow the instructions below in addition to all the usual
precautions, such as turning off power before remo ving logic boards:

Keep the ESD-sensitiv e part in its original shipping container (a

•

special “ESD bag”) until you are ready to install the part into the
machine.

Make the least-possible movements with your body to prevent

•

an increase of static electricity from clothing fibers, carpets, and
furniture.

Put the ESD wrist strap on your wrist. Connect the wrist band to

•

the system ground point. This discharges any static electricity in
your body to the machine.

Hold the ESD-sensitive part by its edge connector shroud

•

(cover); do not touch its pins. If you are removing a pluggable
module, use the correct tool.

Do not place the ESD-sensitive part on the machine cover or on

•

a metal table; if you need to put down the ESD-sensitiv e part for
any reason, first put it into its special bag.

Machine covers and metal tables are electrical grounds. They

•

increase the risk of damage because they make a discharge
path from your body through the ESD-sensitive part. (Large
metal objects can be discharge paths without being grounded.)

Prevent ESD-sensitiv e parts from being accidentally touched by

•

other personnel. Install machine covers when you are not work­ing on the machine, and do not put unprotected ESD-sensitive
parts on a table.

If possible, keep all ESD-sensitive parts in a grounded metal

•

cabinet (case).
Be extra careful in working with ESD-sensitive parts when cold-

•

weather heating is used because low humidity increases static
electricity.

Repair Information 4-1

4044-001

Removal Procedures

CAUTION:

working on the printer with one of the covers removed. Be sure to
remove the print cartridge before you perform removal procedures.

Be sure to unplug the power cord whenever you are

Screw Identification Table

Type 1 Screw Type 2 Screw Type 3 Screw Type 4 Screw

Covers

Front Cover and Face Up Cover

1. Press the cover inward to release it and pull it forward.

4-2 Service Manual

4044-001

2. Remove the face up cover.

3. Open the front cover.

Repair Information 4-3

4044-001

4. Remove the screw from the support.

Note:

screws and then remove the panel board and board cover.

If you want to remove the front cover only, remove the two

4-4 Service Manual

4044-001

Rear and Top Cover

1. Remove the three screws, press the retaining tabs and remove
the rear cover.

2. Remove the front cover and face up cover.

3. Remove the two screws and remove the top cover.

Repair Information 4-5

4044-001

Side Covers

1. Remove the front cover , face up cover, top cover and rear cover.

2. Remove the two screws securing the rear of each side cover.

3. Release the side cover tabs as shown and remove the left and
right side covers.

4-6 Service Manual

4044-001

Frame Assembly

1. Remove all covers.

2. Remove the HVPS.

3. Remove the two screws and remove the solenoid.

4. Remove the six screws and remove the frame assembly.

Repair Information 4-7

4044-001

Fuser Assembly

1. Remove all covers.

2. Remove the wire cover mounting screw (A).

3. Remove the two fuser lamp wire mounting screws (B).

4. Unplug the connector from the engine/LVPS board.

5. Remove the two fuser mounting screws (C).

4-8 Service Manual

4044-001

6. Slide the fuser in the direction of the arrows and remove the
fuser.

Note:

turned on its side with the fuser removed.

The backup roller can fall from the printer if the printer is

Repair Information 4-9

4044-001

HVPS

1. Remove all covers.

2. Remove the four HVPS board mounting screws.

4-10 Service Manual

4044-001

3. Unplug the three cables from the connectors on top of the
HVPS.

4. Unplug the cable from the lower connector inside the HVPS and
remove the HVPS.

Note:

HVPS removed. Three contacts with the shorter springs are
installed in the hole marked L+S. The contact with the longer spring
is installed in the hole marked L+L.

The high voltage contacts can fall from the printer with the

Repair Information 4-11

4044-001

Interconnect Board

1. Remove the LVPS.

2. Unplug all connectors from the interconnect board.

3. Remove the screws and remove the interconnect board.

4-12 Service Manual

4044-001

Engine/LVPS Board

1. Turn the printer upside down.

2. Remove all screws securing the shield.

3. Remove the shield.

Repair Information 4-13

4044-001

4. Unplug all the connectors from the engine/LVPS board.

5. Remove the five screws and remove the engine/LVPS board.

4-14 Service Manual

4044-001

Main Drive Assembly

1. Remove all covers.

2. Remove the six main drive assembly mounting screws.

3. Unplug the connector and remove the main drive assembly.

Repair Information 4-15

4044-001

Pick Roll Assembly

1. Remove all the covers.

2. Remove the high voltage power supply.

3. Remove the roller bearing.

4-16 Service Manual

4044-001

4. Remove the roller access cover.

5. Remove the upper frame.

6. Remove the pick up roller gear and clutch.

7. Lift the pick roll assembly from the printer.

Repair Information 4-17

4044-001

Printhead Assembly

1. Remove the top cover.

2. Unplug all the connectors from the printhead.

3. Remove the four mounting screws and remove the printhead.

4-18 Service Manual

4044-001

Transfer Roll

1. Remove the front cover and face up cover.

2. Remove the transfer roll.

Repair Information 4-19

4044-001

4-20 Service Manual

4044-001

5. Connector Locations

Controller Board

Connector Pin No. Signal

J1 Printhead 1 N/A

2 Ground

U5 Operator Panel
(signals at idle)

J7 Engine/LVPS Board 1 +5 V dc

1 Ground
2 +5 V dc
3 +5 V dc
4N/A
5 +5 V dc
6 Ground

2 +5 V dc
3 +5 V dc
4 +5 V dc
5 +5 V dc
6 +5 V dc
7 Ground
8 +5 V dc
9 +5 V dc
10 +5 V dc
11 Ground
12 +5 V dc
13 +5 V dc
14 +5 V dc

Connector Locations 5-1

4044-001

Connector Pin No. Signal

J7 (continued) 15 +5 V dc

16 +5 V dc
17 +5 V dc
18 Ground
19 Ground
20 Ground
21 Ground
22 Ground
23 +5 V dc
24 +5 V dc

5-2 Service Manual

4044-001

Connector Locations 5-3

4044-001

Engine/LVPS Board

Connector Pin No. Signal

CN201 Power Switch 1 AC In

2AC In

CN202 Fuser Lamp 1 AC In

2AC In

CN1 Thermistor 1 THERM

2 +3.9 V dc

CN2 HVPS/Printhead 1 +24 V dc SWITCH

2 +24 V dc
3 Ground
4 +24 V dc
5VDO
6MHV

5-4 Service Manual

7LDON
8 SUPPLY
9 Ground
10 DEV350

4044-001

Connector Pin No. Signal

CN2 (continued) 11 HSYNC

12 THVPWM
13 EXT CLK
14 Ground
15 Ground
16 THVEA
17 LREADY
18 DEV300
19 P MOTOR
20 +5 V dc
21 AGND
22 AGND
23 THVREAD
24 AGND

Connector Locations 5-5

4044-001

Connector Pin No. Signal

CN4 Interconnect Board 1 DEV FUSE FAN J

2 MOTOR EA J
3 MOTOR PB J
4 MOTOR PA J
5AGND
6 NEW DEV J
7PFEED J
8AGND
9 Ground
10 Ground
11 CLUTCH J
12 PEMPTY J
13 +24 V dc

5-6 Service Manual

14 PNARROW J
15 +5 V dc
16 +24 V dc
17 PTL J
18 +5 V dc
19 PMOTOR EXT J
20 EXT CLK J

4044-001

Connector Pin No. Signal

CN5 Controller Board 1 EBUSY

2Not Used
3EMSG
4 EXITPAP
5CCLK
6PRINT
7VDI
8Not Used
9 PSYNC
10 READY
11 HSYNC
12 Not Used
13 +5 V dc
14 CMSG
15 +5 V dc
16 +5 V dc
17 Ground
18 +5 V dc
19 Ground
20 Ground
21 Ground
22 Ground
23 VDO
24 Not Used

Connector Locations 5-7

4044-001

5-8 Service Manual

4044-001

High Voltage Power Supply

Connector Pin No. Signal

CN1 Engine/LVPS Board 1 +24 V dc

2 +24 V dc SWITCH
3 +24 V dc
4 Ground
5MHV
6VDO
7 SUPPLY
8LDON
9 DEV350
10 Ground
11 THVPWM
12 HSYNC
13 Ground
14 EXT CLK
15 THVEA
16 Ground
17 DEV300
18 LREADY
19 +5 V dc
20 P MOTOR
21 AGND
22 AGND
23 AGND
24 THVREAD

Connector Locations 5-9

4044-001

Connector Pin No. Signal

CN2 Cover Open Switch 1 +24 V dc SWITCH

2Not Used
3 +24 V dc

CN3 Printhead 1 +24 V dc SWITCH

2AGND
3P MOTOR
4LREADY
5EXT CLK

CN4 Printhead 1 HSYNC

2 +5 V dc SWITCH
3 Ground
4LDON
5VDO

5-10 Service Manual

6 Ground

4044-001

Connector Locations 5-11

4044-001

Interconnect Board

Connector Pin No. Signal

CN401 Paper Feed/Paper
Narrow Sensor

CN402 Clutch 1 +24 V dc

CN403 Paper Empty
Sensor

CN404 Developer Fuse 1 DEV FUSE J

CN405 Main Motor 1 OUT A

1PFEED J
2 PNARROW J
3 +5 V dc
4 Ground

2CLUTCH J
1 PEMPTY J
2 +5 V dc
3 Ground

2 +24 V dc

2OUT B
3 +24 V dc
4 +24 V dc
5OUT A*

5-12 Service Manual

6OUT B*