Lexmark Optra C Service Manual

Optra C

SERVICE MANUAL

Document Number SA40-0 897 -01

P/N 69G3225

R. Monahan

Information Development

D22A/035-3

740 New Circle Road N.W.

Lexington, Kentucky 40511

[phone]

This is a development draft, it may contain technical inaccu­racies and typographical errors.

1

Second Edition (March, 1996)

The following paragraph does not apply to the united kingdom or 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 of the publication. Improvements or changes in the
products or the programs described in this publication may be made at any
time. Publications are not stocked at the address given below; requests for
publications should be made to your point of purchase.

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 F95/035-3, 740 New Circle Road, Lexington,
Kentucky 40511, 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.

© Copyright Lexmark International, Inc. 1995, 1996. 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 and in applicable FAR provisions:
Lexmark International, Inc., Greenwich, CT 06836.

Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

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

Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii

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

Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

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

Diagnostic/Maintenance Approach. . . . . . . . . . . . . . . . . . . . . 2-1

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

Operator Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Power-On Self Test (POST). . . . . . . . . . . . . . . . . . . . . . . 2-8

Error Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Error (46) Toner Cartridge Not Installed Correctly . . . . . 2-14

Error (111/112) Fuser, Warm-Up/Temperature Low . . . 2-15

Error (113) Fuser Temperature High . . . . . . . . . . . . . . . 2-16

Error (114) Fuser Failure . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Error (115) Fuser Heater Off . . . . . . . . . . . . . . . . . . . . . 2-17

Error (116) Fuser Unit Missing. . . . . . . . . . . . . . . . . . . . 2-17

Error (117) Fuser Pump Failure . . . . . . . . . . . . . . . . . . . 2-18

Error (121/125) Laser Board Failure . . . . . . . . . . . . . . . 2-20

Error (122) Laser Failure . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Error (123/124) Mirror Motor Start-up or Rotation . . . . . 2-21

Error (126/131) Transfer Drum Motor Failure. . . . . . . . . 2-22

Error (130) Service Motor Error . . . . . . . . . . . . . . . . . . . 2-22

Error (132/133) Main Motor (M2) Start-Up or Rotation. . 2-23

Error (134) Controller Fan Motor Failure . . . . . . . . . . . . 2-23

Error (135) Fuser Unit Fan Motor Failure. . . . . . . . . . . . 2-24

Error (136) Electrical Unit Fan Motor Failure . . . . . . . . . 2-24

Error (141) Power Supply Failure (LVPS 110V or 220V) 2-25

Error (142) Engine Board Memory Failure . . . . . . . . . . . 2-25

Error (143) 5 V / 24 V Supply Failure. . . . . . . . . . . . . . . 2-26

Error (144) Temperature/Humidity Sensor Failure. . . . . 2-26

Error (145) Density Sensor Failure. . . . . . . . . . . . . . . . . 2-26

Error (146) Printer Communication Failure . . . . . . . . . . 2-27

Contents iii

Error (147) Engine Board IC Failure . . . . . . . . . . . . . . . 2-27

Error (148) Developer Unit Rotation Failure . . . . . . . . . 2-28

Error (149) Developer Unit Pressure Failure. . . . . . . . . 2-29

Error (152) Tray 2 Power Failure. . . . . . . . . . . . . . . . . . 2-29

No AC Power/Dead Machine. . . . . . . . . . . . . . . . . . . . . 2-30

No DC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

No Pickup (Manual Feed) . . . . . . . . . . . . . . . . . . . . . . . 2-31

No Pickup (Cassette Feed) . . . . . . . . . . . . . . . . . . . . . . 2-32

No Pickup (Optional Paper Feeder Pickup). . . . . . . . . . 2-32

Registration Roller Does Not Rotate . . . . . . . . . . . . . . . 2-33

High-Voltage Power Supply Output. . . . . . . . . . . . . . . . 2-33

Pickup / Feed System Theory . . . . . . . . . . . . . . . . . . . . 2-34

Paper Feed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Pickup Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Transfer Drum Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

Fuser/Delivery Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Multi-Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

Wrinkles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Leading-Edge Fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

Skewing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Error Codes - 9XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Error (900) Software Error. . . . . . . . . . . . . . . . . . . . . . . 2-46

Error (941) Service ROM SIMM . . . . . . . . . . . . . . . . . . 2-46

Error (939, 942, 943, 944) Service RIP Board. . . . . . . . 2-46

Error (945) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-46

Error (946) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-47

Error (947) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-47

Error (948) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-47

Error (949) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-47

Error (950) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-48

Error (953) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-48

Error (955) Service Video RAM Error . . . . . . . . . . . . . . 2-48

Error (956) Service L2 Cache Error. . . . . . . . . . . . . . . . 2-48

Error (960) Service Memory Error. . . . . . . . . . . . . . . . . 2-48

Error (961) Bad / Missing DRAM. . . . . . . . . . . . . . . . . . 2-49

Error (970/979) INI Failure. . . . . . . . . . . . . . . . . . . . . . . 2-49

Error (977) Service Network Board . . . . . . . . . . . . . . . . 2-49

Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Print Quality Start Of Call . . . . . . . . . . . . . . . . . . . . . . . 2-50

Horizontal Variation (“Jitter”) Example. . . . . . . . . . . . . . 2-53

Print Quality Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 2-55

iv

Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Black Horizontal Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Black Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Blur at Bottom of Page. . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Laser Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Low Color Coverage or Usage. . . . . . . . . . . . . . . . . . . . 2-57

Oil Soaking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Random Oil Spots on Page . . . . . . . . . . . . . . . . . . . . . . 2-59

Spew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Print Quality Service Checks . . . . . . . . . . . . . . . . . . . . . . . . 2-62

Black Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

Blank Page Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-62

Blank Spots Service Check . . . . . . . . . . . . . . . . . . . . . . 2-63

Color Aberration Service Check. . . . . . . . . . . . . . . . . . . 2-64

Dark Image Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-64

Dirt On Back Of Paper Service Check . . . . . . . . . . . . . . 2-65

Dirty Print Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-66

Distortion Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Horizontal Voids Service Check. . . . . . . . . . . . . . . . . . . 2-67

Light Image Service Check . . . . . . . . . . . . . . . . . . . . . . 2-68

Poor Fusing Service Check . . . . . . . . . . . . . . . . . . . . . . 2-69

Spacing Table Service Check . . . . . . . . . . . . . . . . . . . . 2-69

Streaking Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-70

Toner Scattered Service Check . . . . . . . . . . . . . . . . . . . 2-71

Vertical Lines Service Check . . . . . . . . . . . . . . . . . . . . . 2-72

Vertical Voids Service Check . . . . . . . . . . . . . . . . . . . . . 2-73

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

Basic Engine Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Diagnostics Mode Menu Structure . . . . . . . . . . . . . . . . . . 3-3

Diagnostics Mode Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Button Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Flash Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Memory Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Contents v

Print Test 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Print Test 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Print Test 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Wrap Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Other Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Density Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . 3-12

LAN Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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

Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Attraction Roller Drive Assembly. . . . . . . . . . . . . . . . . . . 4-3

Cassette Paper Pickup Drive Motor . . . . . . . . . . . . . . . . 4-4

Registration Roller Drive Clutch . . . . . . . . . . . . . . . . . . . 4-4

Cassette Paper Pickup PCB . . . . . . . . . . . . . . . . . . . . . . 4-5

Cassette Paper Pickup Assembly . . . . . . . . . . . . . . . . . . 4-5

Cassette Paper Pickup D-rollers . . . . . . . . . . . . . . . . . . . 4-6

Cassette Paper Pickup Roller Assembly, Front. . . . . . . . 4-6

Cassette Paper Pickup Roller Assembly, Rear. . . . . . . . 4-6

Cassette Paper Pickup Solenoid. . . . . . . . . . . . . . . . . . . 4-7

Corona Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Cover Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

DC Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Density Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . 4-23

Density Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Developing Rotary Assembly . . . . . . . . . . . . . . . . . . . . 4-24

Discharge Roller Drive Assembly . . . . . . . . . . . . . . . . . 4-25

Drive Gear Solenoid Assembly . . . . . . . . . . . . . . . . . . . 4-26

Drum Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Drum Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Fuser Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Fuser Oil Bottle Case Assembly . . . . . . . . . . . . . . . . . . 4-30

Fuser Hot Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Fuser Thermo Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Fuser Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4-33

Fuser Oil Apply Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-34

Fuser Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Fuser Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

vi

Fuser Oil Applying Input Assembly . . . . . . . . . . . . . . . . 4-40

Fuser Delivery Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-40

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . 4-41

High Voltage Converter . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . 4-42

Main Drive Motor and Board . . . . . . . . . . . . . . . . . . . . . 4-42

Mechanical Controller PCB . . . . . . . . . . . . . . . . . . . . . . 4-43

Multipurpose Feeder Paper Pickup, D-Roller. . . . . . . . . 4-43

Multipurpose Feeder Paper Sensor . . . . . . . . . . . . . . . . 4-43

Multipurpose Feeder U-Turn Roller Assembly . . . . . . . . 4-44

Multipurpose Feeder D-Roller Solenoid . . . . . . . . . . . . . 4-44

Paper Delivery Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4-45

Printhead and Printhead Board . . . . . . . . . . . . . . . . . . . 4-46

Printer Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Rotary Manual Feed Assembly . . . . . . . . . . . . . . . . . . . 4-50

Rear Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Rear Cooling Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Transfer Drum Motor and Developer Drive Motor . . . . . 4-51

Transfer Drum and Holder Assembly. . . . . . . . . . . . . . . 4-52

Transfer Drum Separation Claw. . . . . . . . . . . . . . . . . . . 4-53

Transfer Drum Knob Assembly . . . . . . . . . . . . . . . . . . . 4-53

Transfer Drum Attraction Roller . . . . . . . . . . . . . . . . . . . 4-54

Transfer Drum Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Transfer Drum Front and Rear Slide Assemblies. . . . . . 4-56

Transfer Drum Discharge Roller. . . . . . . . . . . . . . . . . . . 4-56

Transfer Drum HV Contact Assembly . . . . . . . . . . . . . . 4-56

Transfer Drum Gripper Assembly. . . . . . . . . . . . . . . . . . 4-57

Transfer Drum Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Transfer Drum Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Transfer Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Transfer Drum Cleaning Drive Assembly. . . . . . . . . . . . 4-62

Toner Cartridge Ejector . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Upper Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Upper Output Drive Assembly . . . . . . . . . . . . . . . . . . . . 4-64

Video Controller Board. . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Optional Paper Feeder Removals . . . . . . . . . . . . . . . . . . . . 4-65

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

Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

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

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Clutches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Contents vii

Clutches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . 5-9

Motors and Fuser Heaters. . . . . . . . . . . . . . . . . . . . . . . 5-10

Motors and Fuser Heaters . . . . . . . . . . . . . . . . . . . . 5-11

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

PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

DC Controller Board Connector Locations . . . . . . . . . . 5-18

DC Controller Board Connector Locations (Graphic) . . 5-19

Mechanical Controller Board Connector Locations . . . . 5-26

Mechanical Controller Board Connectors (Graphic) . . . 5-27

Paper Pickup Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Optional Paper Feeder (Driver Board). . . . . . . . . . . . . . 5-35

Optional Paper Feeder (Miscellaneous) . . . . . . . . . . . . 5-36

High Voltage Power Supply PCB . . . . . . . . . . . . . . . . . 5-36

Separation HVT PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Ejection Sensing PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Cassette Size Sensing PCB . . . . . . . . . . . . . . . . . . . . . 5-37

Paper Feed Driver PCB. . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Fuser Connector (J21). . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

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

Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

Maintenance, Customer Checks . . . . . . . . . . . . . . . . . . . 6-3

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

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

Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Toner (used) Reservoir/ HV. . . . . . . . . . . . . . . . . . . . . . . . 7-6

Major Assemblies (Top/Bottom) . . . . . . . . . . . . . . . . . . . . 7-8

DC Controller / Video Controller Board . . . . . . . . . . . . . . 7-10

Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Drive, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Density Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Door Switch, Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Door Switch, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Ejector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Solenoid Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Cleaning Belt Drive Solenoid. . . . . . . . . . . . . . . . . . . . . . 7-28

Rotary Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

viii

Printer Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32

Transfer Drum Cleaning Drive . . . . . . . . . . . . . . . . . . . . .7-34

Discharge Roller Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36

Drum Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38

Attraction Roller Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40

Paper Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42

Universal Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44

Paper Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46

Cassette Paper Pickup Asm. . . . . . . . . . . . . . . . . . . . . . .7-48

Multipurpose Feeder Pickup Asm . . . . . . . . . . . . . . . . . .7-52

Paper, Side Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-54

Developing Rotary Asm . . . . . . . . . . . . . . . . . . . . . . . . . .7-56

Transfer Drum Mounting Asm . . . . . . . . . . . . . . . . . . . . .7-58

Transfer Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-60

Density Sensor Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-64

Transfer Drum Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . .7-66

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-68

Video Controller Board. . . . . . . . . . . . . . . . . . . . . . . . . . .7-72

Optional Paper Feeder (Main Body). . . . . . . . . . . . . . . . .7-74

Optional Paper Feeder (Front). . . . . . . . . . . . . . . . . . . . .7-76

Paper Pickup Asm (Base) . . . . . . . . . . . . . . . . . . . . . . . .7-80

Paper Pickup Asm (Rear). . . . . . . . . . . . . . . . . . . . . . . . .7-82

Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-84

Contents ix

x

Preface

This manual is divided into the following chapters:

•

“General Information” contains a general description of the
printer and the maintenance approach used to repair it. Special
tools, test equipment, and options are listed.

•

“Diagnostic Information” contains error code table, symptom
table, and service checks used to isolate failing field replaceable
units (FRUs).

•

“Diagnostic Aids” contains tests and checks used to locate or
repeat symptoms of printer problems.

•

“Repair Information” provides instructions for making printer
adjustments and removing and installing FRUs.

•

“Connector Locations” uses illustrations to identify the major
components and test points on the printer.

•

“Preventive Maintenance” contains safety inspection guide-
lines, lubrication specifications, and maintenance information to
prevent problems and maintain optimum performance.

•

“Parts Catalog” contains illustrations and part numbers for indi­vidual FRUs.

Preface xi

xii

Notices and Safety Information

References in this publication to products, programs, or services do
not imply that the manufacturer intends to make these available in all
countries in which it operates. Any reference to a product, program,
or service is not intended to state or imply that only that product, pro­gram, or service may be used. Any functionally equivalent product,
program, or service that does not infringe any existing intellectual
property rights may be used instead. Evaluation and verification of
operation in conjunction with other products, programs, or services,
except those expressly designated by the manufacturer, are the
user’s responsibility.

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 wavelength region of
770-795 nanometers. The laser system and printer are designed so
there is never any human access to laser radiation above a Class I
level during normal operation, user maintenance, or prescribed
service condition.

Notices and Safety Information xiii

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 .

xiv

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.

Notices and Safety Information xv

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.

xvi

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 bølgelængdeområdet
770-795 nanometer. Lasersystemet og printeren er udformet
således, at mennesker aldrig udsættes for en laserstråling over
Klasse I-niveau ved normal drift, brugervedligeholdelse eller
obligatoriske servicebeting els er.

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.

Notices and Safety Information xvii

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 utformade 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.

xviii

Avís sobre el Làse r

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.

Notices and Safety Information xix

Japanese Laser Notice

Chinese Laser Notice

xx

Korean Laser Notice

Notices and Safety Information xxi

Trademarks

Optra and Lexmark are trademarks of Lexmark International, Inc.
AppleTalk and LocalTalk are trademarks of Apple Computer, Inc.,

registered in the United States and other countries.
PCL® is a registered trademark of the Hewlett-Packard Company.

PCL 5 is Hewlett-Packard Company’s designation of a set of printer
commands (language) and functions included in its printer products.
This printer is intended to be compatible with the PCL 5 language.
This means the printer recognizes PCL 5 commands used in various
applications programs, and that the printer emulates the functions
corresponding to the commands.

Details relating to compatibility are included in the Technical
Reference manual.

Other trademarks are the property of their respective owners.

xxii

Safety Information

•

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.

•

The safety features of some parts may not always be
obvious. Therefore, replacement parts must have the
identical or equivalent characteristics as the original parts.

Sicherheitshinweise

•

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.

•

Ersatzteile müssen gleiche oder gleichwertige Merkmale wie
die Originalteile aufweisen, da nicht immer offensichtlich ist,
welche Teile des Geräts Sicherheitsmerkmale aufweisen.

Notices and Safety Information xxiii

Consignes de Sécurité

•

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.

•

Les normes de sécurité de certaines pièces n'étant pas
toujours explicites, les pièces de rechange doivent être
identiques ou conformes aux caractéristiques des pièces
d'origine.

Norme di sicurezza

•

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.

•

Poiché non tutti i pezzi di ricambio garantiscono la stessa
sicurezza, questi devono avere caratteristiche identiche o
equivalenti a quelle dei pezzi originali.

xxiv

Pautas de Seguridad

•

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.

•

Los dispositivos de seguridad de algunas piezas no siempre
pueden reconocerse a simple vista. Por lo tanto, los
recambios deben poseer características idénticas o
equivalentes a las de las piezas originales.

Informações de Segurança

•

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.

•

Os dispositivos de segurança de algumas peças poderão
não ser sempre suficientemente evidentes. Assim, as peças
sobressalentes devem possuir características idênticas ou
equivalentes às peças originais.

Notices and Safety Information xxv

Informació de Seguretat

•

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

•

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

•

Les característiques de seguretat d’algunes de les peces
poden no ser òbvies. Per tant, les característiques dels
recanvis hauran de ser idèntiques o equivalents a les de les
peces originals.

xxvi

Chinese Safety Information

Korean Safety Information

Notices and Safety Information xxvii

1. General Information

The Optra C is a 600 dpi Color Laserprinter designed to attach to
IBM-compatible PC’s and to most types of computer networks. The
one model is available with standard PostScript Level 2 emulation
and PCL 5 emulation:

Print speed in
pages per minute

A4 Full Color

3 12 2.5

A4 Mono
Color

A4 Full Color
Fine Mode

Power Consumption

Max. A/C draw 110 V 1.1kW
Max. A/C draw 220 V 1.0kW

Options

The following options are available. Some options are not available
in ev ery country. Contact your point of purchase for options available
in your country.

Memory upgrade options of 2MB, 4MB, 8MB, 16MB and 32MB.
Flash memory options of 1MB, 2MB and 4MB
Integrated network options

Token-Ring

Ethernet
Second drawer option (tray 2)
Internal disk option

General Information 1-1

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

This printer can be serviced without being connected to a host
computer.

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

When the message “80 scheduled maintenance” appears, replace
the following parts:

Note: At 60k prints or less, depending on the number of transparen­cies.

Fuser Assembly (see assembly 32-1)
Air Filter (see assembly 1-24)
Ozone Filter (see assembly 7-30)
Separation Corona (see assembly 30-5)
Drum Cleaning Assembly (see assembly 31-1)

Also, it is recommended the following parts be replaced at the
indicated intervals:

100k - Multipurpose Tray Pickup Roller (see assembly 25-3)
100k - Separation Pad (see assembly 25-5)
100k - Rear Feed Roller (see assembly 24-7)
100k - Front Feed Roller (see assembly 24-4)
200k - Cassette Pickup Roller (see assembly 24-2)

1-2

Service Checkpoints

Fuser Unit

Point Tool/Solvent Remarks

Delivery Guide MEK Clean lightly to remove

toner.

Separation
Claw Unit

MEK Clean carefully, the tip

breaks easily.

Entrance Guide MEK Clean

Cassette Pickup Unit

Point Tool/Solvent Remarks

Feed Roller
Separation

Damp towel
or alcohol

Clean

Roller

Transfer Drum Holder Unit

Point Tool/Solvent Remarks

Transfer Sheet Lint free paper Clean, do not use water or

solvents and do not
contaminat e with solv ents or
oil.

General Information 1-3

Drum Cartridge

Point Tool/Solvent Remarks

Photoconductor Toner Clean, do not use water or

solvents and do not
contaminate with solvents or
oil. When removing the
drum store it in the drum
cover.

Manual Feeding Tray Pickup Unit

Point Tool/Solvent Remarks

Separation Pad Dry towel Clean

Density Sensor Unit

Point Tool/solvent Remarks

Density Sensor
Window

Separation
Charging Unit

Specialty
brush

Specialty
brush

Clean

Clean

1-4

Tools

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

•

Magnetic tip Phillips screwdrivers large and small

•

Flat-blade screwdriver

•

Fuse puller

•

Analog or digital volt ohmmeter

•

Oil syringe and bottle

•

Drop cloth

•

Grease

•

Cleaning tissue

•

Magnifier

•

Gloves

•

Retaining ring pliers

•

Ruler

Refer to the parts catalog for part numbers of special tools. When
taking voltage readings, always use frame ground unless another
ground is specified.

General Information 1-5

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 Network
LASER Light Amplification by Stimulated Emission of

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

1-6

2. Diagnostic Information

Diagnostic/Maintenance Approach

This printer can be serviced without being connected to a host
computer.

This printer will display both operator correctable errors and service
errors on the front (operator) panel. In addition, there are tests
available from the density adjustment panel on the back of the
machine that bypass the video controller board. These basic engine
function tests to enable you to eliminate potential software problems.
These tests are covered in Chapter 3, “Diagnostic Aids”.

Using the diagnostic information in this manual leads you to the
correct field replaceable unit (FRU), or part. Before replacing an
entire FRU, determine if just the defective part is available in the
parts section, Chapter 7. Always replace the smallest possible part.
Use the error code charts, symptom index, service checks and the
diagnostic aids chapter to determine the symptom and repair the
failure. After you complete the repair, perform the appropriate tests
to verify the repair.

DO NOT swap parts as a diagnostic technique. Certain parts work
as a system and unnecessary swapping of these parts may lead to
print quality.

Diagnostic Information 2-1

DC Controller Board Information

The DC controller board (DCCB) controls the printer. When the
PRINT signal is received from the video controller board, the DCCB
sends the print sequence command to the mechanical controller
board (MCB) which starts controlling the various loads.

The DC controller board retains important information in EEPROM
concerning drum life, oil out warnings, registration adjustments, and
so on. In addition, this board contains proprietary information and
should be replaced ONLY when directed by the appropriate service
check.

The DC controller board also provides:

•

Laser/Scanner control

•

Image stabilization control (environmental, toner quality,
photoconductor drum life)

•

Fuser temperature control

•

Power-OFF time measurement

•

Various detection functions

•

Video interface control

2-2

Mechanical Controller Board Information

The mechanical controller board (MCB) controls the various loads in
response to signals received from the DC controller board (DCCB).
The MCB then returns the status signals to the DCCB. The MCB
controls the pick-up PCB, the high voltage power supply PCB, and
the paper feeder driver PCB by way of the serial communication.

The mechanical controlle r boa rd also provide s:

•

Drive for the various motors and fan motors

•

Control of the toner carousel, fuser transfer drum and peripheral
units

•

Toner stirring, toner low detection and toner cartridge detection

•

Photosensitive drum life detection

•

Waste toner collect system control

•

Power saving mode control

Note: There are two non-replaceable fuses on the MCB. They are
labeled FU2001 and FU2002. If a short occurs on the various
solenoids, or if you ground the wrong side, these fuses could open.

Diagnostic Information 2-3

Start

Use the error message table, symptom table, service checks, in this
chapter and the diagnostic aids in Chapter 3 to determine the
corrective action to repair a printer.

If the operator panel is blank, black or appears unusual, unplug the
video controller board and run the engine print tests using the
Density Adjustment Panel. Go to Chapter 3 “Diagnostic Aids” to start
the call since the operator panel or video controller board may have
a defect.

If an error is displayed, locate it in the following “error message
table” and take the appropriate action.

If your machine does not have an error code and does not complete
P ower-On Self Test (POST), go to POST and the POST symptom
table. If your machine makes it through POST without an error but
you have a symptom, go to the symptom table, locate your symptom
and take the appropriate action.

If an error message appears while you are working on the printer , go
to the error message table and take the indicated action.

Note: Some of the following service checks require voltage and/or
continuity readings. For continuity readings, turn off and unplug the
printer or optional sheet feeder. F or voltage measurements, close
the front door and be sure the door micro switch is in the closed
position.

WARNING: It is possible for the printer to enter POST or print tests
with all covers removed (except the front cover) and the door switch
closed.

2-4

Operator Codes

The following code numbers are operator instructions and
messages. In some cases, no action is required; others are
operator-correctable; and others may require service. An error code
may require up to one minute to appear. Some symptoms may not
generate an error code. Locate your symptom in the table and take
the indicated action.

Code Symptom

20 - 25 Paper Jam

When experiencing repeated or non resetable paper jam codes,
go to “Paper Feed Troubleshooting” on page 2-38.

26 Incorrect Paper Size

Ensure that the size of the paper being fed matches the size of
the paper selected in the paper setup menu, and the gates in the
cassette. Also check the cassette size sensing PCB and the
ejection sensing PCB. Refer to the Block Wiring Diagram Sheet.

27 Change Paper

The LCD displays the following paper sizes:
(Letter, Legal, B5, A4)

28 Load Paper

Ensure there is pa per in t he tray(s). If paper is pres en t, c heck the
operation of the cassette paper sensor, PS301.

30 Door Open

There is only one door open switch. It is locate d ab o ve the LVPS.
It is a mechanical “and gate”. The front door, fuser access door
and paper feed mechanism must all be closed to actuate this
switch. Rem o ve the rear cover and EMC s hie ld. Trace the motion
of the interlocks and repair as necessary.

31 - 34 Cartridge Missing

If all cartridges are incorrectly reported missing, check

• The toner low detect PCB (Beam)

• The toner low detect PCB (Receiver)

• The density sensor ribbon cable

:

35 Cartridge Eject Handle Out

Check the mec hanical op eration of the cartridge eject le v er . If thi s
is OK, chec k the e jectio n sens ing PCB for damage to the ejectio n
sensing switch.

Diagnostic Information 2-5

Code Symptom

41 Waste Bottle Full

Check for

:

• Full bottle

• Improper installation

• Missing bottle

• Broken interlock

• Toner on window of bottle (Use a clean, dry rag to clean the
window. Do not use finger.)

42 Oil Bottle Empty/Missing

Check to ensure the bottle is not empty. If the bottle has oil,
remove the fuser and verify the float ball in the oil bottle case is
following the level of the oil. Check the operation of the oil sensor
PCB in the machine, (it is not in the fuser) .

43 Photoconductor Unit Missing

Ensure that the photoconductor unit i s completely seated in the
machine. Check the continuity from J1004-5 on the HVPS to the
spring that contacts the pad on the rear of the photoconductor.
There is a resistor of approximately ± 9K ohms in this line.

44 Fuser Life Exhausted

Remove the fuser from the printer . Rem o ve the yellow co ver from
the top of the fuser and v erify that the cl eanin g we b is e xhaus ted.
A notch at the life limit of the web allows an arm to drop, which
bloc ks a sensor located on the printer , (not the fus er) near the e xi t
drive mechanism. If the web is exhausted, drain the fuser oil and
replace the fuser. If the arm has prematurely dropped, (or if the
customer has pushed it down), reset the arm on top of the web
and reinstall the fuser.

Note:

Fuser replacement is the responsibility of the customer.

45 Paper Feed Mechanism Missing

Either the paper feed mechanism has not been securely latched
into the machine or there is a problem with the self docking
connector.

2-6

Code Symptom

46 Toner Cartridge Not Correctly Installed

If there is a problem with one or more toner cartridges,
check the following:

1. The latch at the rear that keeps the cartridge cover locked.

2. The hook at the rear that locks the cartridge into the rotary
assembly .

3. The three color-keyed locating pins in the front of the cartr idge
(that face to the rear).

4. If a good cartridge causes Code 46 to display, see “Error (46)
Toner Cartridge Not Installed Correctly” on page 2-14.

80 Scheduled Maintenance - see Code 44.
83 Photoconductor Unit Life Warning

The photoconductor is nearing end-of-life. Do not replace the
photoconductor with another used unit for troubleshooting
purposes. If a new unit is installed and the code 83 message

remains, carefully check the density sensor ribbon cable.
84 Oil Bottle Low - see Co de 42.
85 - 88 Toner Low

Remove and gently shake the car tridges. This may allow

additional usage. At this point, print quality may have degraded

and background will become more pronounced (end-of-life).

If this code applies to one cartridge which is known to be new,

check the two windows on the cartridge for damage or debris.

If the machine reports all cartridges low, check the toner low

detect PCT (Beam) a nd ton er lo w detect PCB (Receive) . Re fer to

the Block Wiring Diagram Sheet.

Diagnostic Information 2-7

Power-On Self Test (POST)

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

1. All Operator Panel segments turn on from the top row down
then clear.

2. Diamonds fill the display and then clear.

3. The Fuser Lamps and Fans turn on and “Performing Self Test”
appears on the display.

Note: If there is a fault with the printer, the machine will termi­nate the POST within 10 seconds, the machine beeps, and the
Error Code will be displayed within 35 seconds.

4. The Developing Rotary Assembly Drive Motor turns on and
rotates the assembly to the first homing position.

5. The Developing Rotary Assembly is indexed one position at a
time looking for missing cartridges. If a cartridge is missing, the
Developing Rotary Assembly stops at that position and prompts
the operator to load the cartridge, POST continues.

6. The Main Drive Motor turns on and drives the Fuser Exit
mechanism (depending upon the temperature of the Fuser).

7. The Transfer Drum Drive Motor is energized, the Transfer Drum
Engagement and Cleaning Brush Engagement solenoids pick
within 10 seconds, and 5 seconds later, the Cleaning Brush
Motor is energized.

8. The Display reads “Busy”.

9. Each Cartridge in turn is pressed into the development position,
stirred and checked for low toner.

10. The Laser Scan Motor is energized.

11. Each cartridge in turn is indexed into the development position,
and pressed against the PC.

12. Each cartridge (starting with Magenta) lays down a series of
small (< 1 “) squares of toner directly on the Transfer Drum for
calibration purposes. These patches start at MAXIMUM density
and drop to half tones. The black patches are laid down on the
white portion of the drum.

2-8

13. After the patches are read by the Density Sensor, the Cleaning
Brush mechanism is pressed against the drum and the
Cleaning Brush Motor is energized.

14. The calibration process is repeated this time starting at
MINIMUM density and going to MAXIMUM density. At the end
of this cycle the Cleaning Brush Mechanism is pressed and the
Cleaning Brush Motor is energized.

15. Drive motors stop, all fans stay on.

Note: If any of the supplies need attention, a message will be
displayed at this time.

16. The Display reads “Ready”.

Diagnostic Information 2-9

Error Message Table

Error Message Action

46 Toner cartridge not

correctly installed

111 Fuser, warm-up

Temperature low

112 Fuser, warm-up

Temperature low

113 Thermistor short See “Error (113) Fuser Temperature

114 Fuser See “Error (114) Fuser Failure” on

115 Fuser upper heater /

Thermoswitch

116 Fuse r unit missing See “Error (116) Fuser Unit Missing”

117 Fuser pump failure See “Error (117) Fuser Pump

See “Error (46) Toner Cartridge Not
Installed Correctly” on page 2-14.

See “Error (111/112) Fuser, Warm­Up/Temperature Low” on page 2-15.

See “Error (111/112) Fuser, Warm­Up/Temperature Low” on page 2-15.

High” on page 2-16.

page 2-16.
See “Error (115) Fuser Heater Off”

on page 2-17.

on page 2-17.

Failure” on page 2-18.

121 Laser board failure See “Error (121/125) Laser Board

Failure” on page 2-20.

125 Laser board failure See “Error (121/125) Laser Board

Failure” on page 2-20.

122 Laser failure See “Error (122) Laser Failure” on

page 2-20.

123 Mirror motor start-up

or rotation

124 Mirror motor start-up

or rotation

126 Transfer drum motor

failure

130 Service motor error See “Error (130) Service Motor

131 Transfer drum motor

failure

See “Error (123/124) Mirror Motor
Start-up or Rotation” on page 2-21.

See “Error (123/124) Mirror Motor
Start-up or Rotation” on page 2-21.

See “Error (126/131) Transfer Drum
Motor Failure” on page 2-22.

Error” on page 2-22.
See “Error (126/131) Transfer Drum

Motor Failure” on page 2-22.

2-10

Error Message Action

132 Main motor start-up or

rotation

See “Error (132/133) Main Motor
(M2) Start-Up or Rotation” on pa ge
2-23.

133 Main motor start-up or

rotation

See “Error (132/133) Main Motor
(M2) Start-Up or Rotation” on pa ge
2-23.

134 Controller fan motor

failure

135 Fuser unit fan motor

failure

136 Electrical unit fan motor

failure

See “Error (134) Controller Fan
Motor Failure” on page 2-23.

See “Error (135) Fuser Unit Fan
Motor Failure” on page 2-24.

See “Error (136) Electrical Unit Fan
Motor Failure” on page 2-24.

141 Power supply failure See “Error (141) Power Supply

Failure (LVPS 110V or 220V)” on
page 2-25.

142 Engine board memory

failure

See “Error (142) Engine Board
Memory Failure” on page 2-25.

143 5v / 24v Supply failure See “Error (143) 5 V / 24 V Supply

Failure” on page 2-26.

144 Temperature / humidity

sensor fai lur e

See “Error (144) Temperature/
Humidity Sensor Failure” on page
2-26.

145 Density sensor failure See “Error (145) Density Sensor

Failure” on page 2-26.

146 Printer communication

failure

See “Error (146) Printer
Communication Failure” on page
2-27.

147 Engine board IC failure See “Error (147) Engine Board IC

Failure” on page 2-27.

148 Developer unit rotation

failure

149 Developer unit

pressure failure

See “Error (148) Developer Unit
Rotation Failure” on page 2-28.

See “Error (149) Developer Unit
Pressure Failure” on page 2-29.

152 Power failure See “Error (152) Tray 2 Power

Failure” on page 2-29.

Diagnostic Information 2-11

Symptom Table

Symptom Action

Background Go to “Background” on page 2-55
Black Go to “Black Service Check” on

page 2-62

Blank Page Go to “Blank Page Service Check”

on page 2-62

Blank Spots Go to “Blank Spots Service Check”

on page 2-63

Color Aberration Go to “Color Aberration Service

Check” on page 2-64

Dark Image Go to “Da rk Image Service Check”

on page 2-64

Dead Machine Go to “No AC Power/Dead

Machine” on page 2-30

Dirt On Back Of Paper Go to “Dirt On Back Of Paper

Ser vice Check” on page 2-65

Dirty Go to “Dirty Print Service Check”

on page 2-66

Distortion Go to “Distortion Service Check” on

page 2-67

Folds On Top Of Paper Go to “Leading-Edge F old” on page

2-44

Horizon tal Voids Go to “Ho rizontal Voids Service

Check” on page 2-67

Light Image Go to “Light Image Service Check”

on page 2-68
Multiple Sheet Feeds Go to “Multi-Feed” on page 2-43
No Cassette Feed Go to “No Pickup (Cassette Feed)”

on page 2-32
No DC Power Go to “No DC Power” on page 2-31
No High Voltage Go to “High-Voltage Power Supply

2-12

Output” on page 2-33

Symptom Action

No Manual Feed Go to “No Pickup (Manual Feed)”

on page 2-31

No Optional Feeder Paper Pickup Go to “No Pickup (Manual Feed)”

on page 2-31

Paper Feed Problems In Pickup
Area

Paper Feed Problems In Dr um
Area

Paper F e ed Prob lem s In Fuser an d
Delivery Area

Go to “Paper Feed
Troubleshooting” on page 2-38

Go to “Transfer Drum Unit” on page
2-40

Go to “Fuser/Deli very Unit” on page

2-41
Code 25, Paper Jam Message Will
Not Reset

Poor Fusing Go to “Poor Fusing Service Check”

on page 2-69
Registration Roller Not Turning Go to “Registration Roller Does Not

Rotate” on page 2-33
Skew Go to “Skewing” on page 2-45
Streaking Go to “Streaking Service Chec k” on

page 2-70
Toner Scatter Go to “Toner Scattered Service

Check” on page 2-71
Vertical Lines Go to “Vertical Lines Service

White Vertical Lines Go to “Vertical Lines Service

Wrinkled Paper Go to “Wrinkles” on page 2-44

Check” on page 2-72

Check” on page 2-72

Diagnostic Information 2-13

Service Checks

Error (46) Toner Cart ridge Not Installed Correctly

FRU Action

1 Cartridge(s) Check for broken locating pins. If the cartridge

appears OK, try a different one or set.

2 Carousel brake Check the brake clutch (Asm 16, Ref 9) for

continuity. Check the wiring to the mechanical
controller board.

3 Mechanical

controller PCB.

Replace the mechanical controller PCB.

2-14

Error (111/112) Fuser, Warm-Up/Temperature Low

FRU Action

1 Poor

connection

2 Thermistor/

wiring

3 Fuser upper

heater/
thermoswitch

4 Fuser lower

heater/
thermoswitch

Check the connections of DC controller PCB
connector J112 and mechanical controller PCB
connector J2007.

Turn the power switch OFF, remove the fuser unit,
and measure the resistance between fuser unit
connectors J21-5 and J21-6, see “Fuser Connector
(J21)” on page 5-39. Is it between 180 Ohms and
280 Ohms (normal temperature)? Check the wiring
between DC controller connector J112 and the
thermistor, and if it is normal, replace the thermistor.

Is there continuity between fuser unit connectors
Thermoswitch J21-1 and J21-2 when the fuser unit
is removed? See “Fuser Connector (J21)” on page
5-39. Check the continuity of both the fuser upper
heater and the thermoswitch, and replace defective
parts.

Is there continuity between fuser unit connectors
Thermoswitch J21-3 and J21-4 when the fuser unit
is removed? See “Fuser Connector (J21)” on page
5-39. Check the continuity of both the fuser lower
heater and the thermoswitch, and replace defective
parts.

Reconnect them.

5 Thermistor

mounting

6Thermistor

soiled

7 Power supply

unit (low
voltage )

DC controller
PCB/
Mechanical
controller PCB

Is the thermistor uniformly connected to the fuser
lower roller?

Is the thermistor surface contacting the fuser roller
soiled? Clean it.

Replace the power supply unit. If the problem
remains, replace and check as follows:

1. DC controller PCB, see “DC Controller Board
Information” on page 2- 2.

2. Mechanical controller PCB.

Diagnostic Information 2-15

Error (113) Fuser Temperature High

FRU Action

1 Thermistor

short

2 DC controller

PCB
Mechanical

controller PCB

Turn the power switch OFF, and remove the fuser
unit. Measure the resistance between fuser unit
connectors J21-5 and J21-6, see “Fuser Connector
(J21)” on page 5-39. Is it 1 Ohm or less? Check the
wiring between DC controller PCB connector J112
and the thermistor, and if it is nor m al, replace the
thermistor.

Replace and check as follows:

1. DC controller PCB, see “DC Controller Board
Information” on page 2-2.

2. Mechanical controller PCB.

Error (114) Fuser Failure

FRU Action

1 Fuser Replace the fuser unit.

Note: Error 114 is stored in the DC Controller Board memory. It will
not allow the machine to POR for 30 minutes. The memory can be
reset to see if the error returns. To reset the memory do the
following:

1. Turn the machine off.

2. Short JP101 to ground with a volt meter lead, and remove the
lead.

3. Turn the machine on and see if the error appears.

4. If it reappears, perform steps 1 and 2, then replace the fuser
assembly.

2-16

Error (115) Fuser Heater Off

FRU Action

1 Fuser upper

heater /
Thermoswitch

2 Fuser lower

heater /
Thermoswitch

3 Power supply

unit (low
voltage )

DC controller
PCB

Mechanical
controller PCB

Turn the power switch OFF, and remove the fuser
unit. Is there continuity betw een fuser unit
connectors J2 1-1 and J21-2 ? See “Fuser Conne ctor
(J21)” on page 5-39 . Check the con tinuity of bo th the
fuser upper heater and the thermoswitch, and
replace defective parts.

Is there continuity between fuser unit connectors
J21-3 and J21-4 when the fuser unit is removed?
See “Fuser Connector (J21)” on page 5-39. Check
the continuity of both the fuser lower heater and the
thermoswitch, and replace defective parts.

Replace the p ow er suppl y unit. I f the f ai lure rema ins,
replace and check as follows:

1. DC controller PCB, see “DC Controller Board
Information” on page 2- 2.

2. Mechanical controller PCB.

Error (116) Fuser Unit Missing

FRU Action

1 Fuser Ensure the fuse r unit is secure an d making electrical

contact.

Diagnostic Information 2-17

Error (117) Fuser Pump Failure

Note: This printer must be absolutely level. If it is tipped more than

1 degree to the right and/or rear, the suction pump will not function
correctly and the printer will report a 117 fuser error.

Before starting the diagnostic procedure, do the following:

1. Be sure the printer is lev el.

2. Turn the printer off and remove the oil bottle.

3. Use the suction tool to remove as much oil as possible from the
reservoir.

4. Pump the fuser manual lever 30 or 40 times.

5. Repeat steps 3 and 4 until no additional oil is pumped into the
reservoir.

6. Reinstall the oil bottle, close the covers and turn the printer on.

7. The printer should complete POST. If a 117 error is reported
while running test pages, continue with the following service
check.

If you lev el the printer and the 117 error does not re-appear within 25
pages, end the call.

Use of a spray contact cleaner in most instances will allow normal
functioning of the fuser sensors, which have been contaminated with
silicone oil. The only cleaner currently approved by Lexmark is CRC
brand industrial contact cleaner # 03130.

2-18

In addition to the cautions on the Material Safety Data Sheet
(MSDS) label attached to the can, observe the following guidelines:

•

When spraying either fuser sensor (PS9 or PS10), place a piece
of absorbent material below the sensor to catch the excess
spray.

•

Use the supplied nozzle and direct the spray into the small
apertures in the inside walls of the sensors.

•

Spray quickly (approximately 1 second applications).

This spray leaves no residue, contains no CFCs and is plastic safe.
Do Not use a substitute spray that has not been tested and is not
plastic safe.

FRU Action

1 Float Ensu re the oil float is no t catching on its housing and

is free to move.

2Poor

connection/
Dirty Sensor

3 Fuser unit oil

supply route

4 Fuser unit

Mechanical
controller PCB

DC controller
PCB

Check the connections on the oil overflow sensor
connector J29, fuser uni t connector J21, (see “Fus er
Connector (J21)” on page 5-39) and mechanical
controller PCB connector J2009. Reconnect them
and replace sensor PS10.

Is the hose between the oil supply bottle and the
gear pump plugged up? Clean or replace the parts.

Replace the fuser unit. If the problem remains,
replace and check as follows:

1. Mechanical controller PCB.

2. DC controller PCB, see “DC Controller Board
Information” on page 2- 2.

Diagnostic Information 2-19

Error (121/125) Laser Board Failure

Note: A 125 error may occur due to temperature extremes and may

be of a temporary nature.
Check the error log

•

If it is a one time occurrence, POR the printer to see if it resets.

•

If it has occurred multiple times, replace the laser FRU.

FRU Action

1 Laser/scanner

unit
DC controller

PCB

.

Check the connections on the DC controller
connectors J102, J110, and J111. Go to the
“Horizontal Voids Service Check” on page 2-67.

Check the connections on the laser driver PCB
connectors J401 and J402.

Check the connection on the PCB connector J451.
Replace and check as follows:

1. Laser/scanner unit.

2. DC controller PCB, refer to
“DC Controller Board Information” on page 2-2.

Error (122) Laser Failure

FRU Action

1 Laser/scanner

unit

DC controller
PCB

Check the DC controller PCB connectors J110 and
J111. Check the connections on the laser driver PCB
connectors J401 and J402.

Replace and check as follows:

1. Laser/scanner unit.

2. DC controller PCB, see “DC Controller Board
Information” on page 2-2.

2-20

Error (123/124) Mirror Motor Start-up or Rotation

FRU Action

1Poor

connection

2 Power supply

unit (low
voltage )

3 Laser/scanner

unit
DC controller

PCB

Check the connection on the DC controller PCB
connector J102. Reco nnect it.

Are there approximately 24 V dc between DC
controller PCB connectors J102-10 (24 V) and
J102-5 (GND)? Check whether +24 V dc is being
supplied betw e en DC con trol ler PCB connectors
J101-4 (24 V) and J101-3 (GND). If it is not, replace
the power supply unit.

Test print a page. Does the voltage between DC
controller PCB connectors J102-8 and J102-7
(GND) change from about 5 V dc to OV?

If yes, replace the laser/scanner unit.
If no, replace the DC controller PCB,

see “DC Controller Board Information” on page 2-2.

Diagnostic Information 2-21

Error (126/131) Transfer Drum Motor Failure

FRU Action

1Poor

connection

2 Door switch Turn the machine off and unplug the power cord.

3Drum motor

Mechanical
controller PCB

4 Transfer drum

top sensor
DC controller

PCB

Check the connection on the mechanical controller
PCB connector J2015. Reconnect it.

Disconnect co nnector J7 fro m the powe r supply unit.
When you tur n the door switch (SW2) ON, is there
continuity between connectors J7-1 (+24VB) and
J7-2 (+24VA)? Replace the door switch.

Watch the drum motor during POST. Does it rotate?
Replace and check as follows:

1. Drum motor.

2. Mechanical controller PCB.

Check the connection on the transfer drum top
sensor connector J43. Replace and check as
follows:

1. Transfer drum top sensor.

2. DC controller PCB, see “DC Controller Board
Information” on page 2-2.

Error (130) Service Motor Error

FRU Action

1 Mechanical

controller PCB

2-22

Replace the mechanical controller PCB.

Error (132/133) Main Motor (M2) Start-Up or Rotation

FRU Action

1Poor

connection

2 Door switch Turn the machine off and disconnect the power cord.

3 Main motor

Mechanical
controller PCB

Check the connection on the mechanical controller
PCB connector J2013. Reconnect it.

Disconnect co nnector J7 from the power s upply unit.
When you tur n the door switch (SW2) ON, is there
continuity between connectors J7-1 (+24VB) and
J7-2 (+24VA)? Replace the door switch.

About one minu te after turning th e pow er s witch ON,
does the voltage between mechanical controller
PCB connectors J2013-3 and J2013-4 (GND)
change from about 5 V dc to OV? If yes, repl ac e the
main motor. If not, replac e the mechanical controll er
PCB.

Error (134) Controller Fan Motor Failure

FRU Action

1 Connection Check the connection of mechanical controller PCB

connector J2010. Reconnect it.

2 Controller fan

Mechanical
Controller PCB

Turn the machine off. Disconnect mechanical
controller PCB connecto r J201 0. Immedi ately after
turning the power switch ON, does t he voltage
between mechanical controller PCB connectors
J2010-3 and J2010-1 (GND) change from OV to
about 22 V dc?

If yes, replace the controller fan.
If no, replace the mechanical controller PCB.

Diagnostic Information 2-23

Error (135) Fuser Unit Fan Motor Failure

FRU Action

1Poor

connection

2 Fuser unit fan

Mechanical
controller PCB

Check the connection of mechanical controller PCB
connector J2012. Reconnect it.

Turn the machine off. Disconnect mechanical
controller PCB connector J2012. Immediately after
turning the power switch ON, does the voltage
between mechanical controller PCB connectors
J2012-3 and J2012-1 (GND) change from OV to
about 24 V dc?

If yes, replace the fuser unit fan.
If no, replace the mechanical controller PCB.

Error (136) Electrical Unit Fan Motor Failure

FRU Action

1Poor

connection

Check the connection of mechanical controller PCB
connector J2019. Reconnect it.

2 Electrical unit

fan
Mechanical

controller PCB

Turn the machine off. Disconnect mechanical
controller PCB connector J2019. Immediately after
turning the power switch ON, does voltage between
mechanical controller PCB connectors J2019-3 and
J2019-1 (GND) change from OV to about 24 V dc?

If yes, replace the mechanical unit fan.
If no, replace the mechanical controller PCB.

2-24

Error (141) Power Supply Failure (LVPS 110V or 220V)

FRU Action

1 Wrong fuser

unit
(New fuser or
machine)

2 Fuser upper

heater /
thermoswitch

3 Fuser lower

heater /
thermoswitch

4 Power supply

unit (low
voltage )

DC controller
PCB

Turn the power switch OFF, and remove the fuser
unit. Do the power supply rated voltage and fuser
unit rated voltage correspond? Replace the fuser
unit so that it corresponds to the power supply rated
voltage.

Is there continuity between fuser unit connectors
J21-1 and J21-2 when the fuser unit is removed?
Check the continuity of both the fuser upper heater
and the thermoswitch, and replace defective parts.

Is there continuity between fuser unit connectors
J21-3 and J21-4 when the fuser unit is removed?
Check the continuity of both the fuser lower heater
and the thermoswitch, and replace defective parts.

Replace and check as follows:

1. Power supply unit.

2. DC controller PCB, see “DC Controller Board
Information” on page 2-2.

3. Mechanical controller PCB.

Mechanical
controller PCB

Error (142) Engine Board Memory Failure

FRU Action

1 DC controller

PCB

Replace the DC controller PCB, see “DC Controller
Board Information” on page 2-2.

Diagnostic Information 2-25

Error (143) 5 V / 24 V Supply Failure

FRU Action

1 Power supply

unit (low
voltage)

DC controller
PCB

Check the connections on the DC controller PCB
connector J10 1 and pow er supply u nit connec tor J4.
Replace and check as follows:

1. Power supply unit.

2. DC controller PCB see “DC Controller Board
Information” on page 2-2.

Error (144) Temperature/Humidity Sensor Failure

FRU Action

1 Temperature/

humidity
sensor unit

Mechanical
controller PCB

DC controller
PCB

Check the connections on the temperature/humidity
sensor unit connector J73, connector J15, and
mechanical controller PCB connector J2005.
Replace and check as follows:

1. Temperature/humidity sensor unit.

2. Mechanical controller PCB.

3. DC controller PCB, see “DC Controller Board
Information” on page 2-2.

Error (145) Density Sensor Failure

FRU Action

1 Density sensor

unit / cable

DC controller
PCB

2-26

Check the connections on the density sensor unit
PCB connector J501 and DC controller PCB
connector J103.

Replace and check as follows:

1. Cable.

2. Density sensor unit.

3. DC controller PCB, see “DC Controller Board
Information” on page 2-2.

Error (146) Printer Communication Failure

FRU Action

1 Paper feeder

(printer)

2 Mechanical

controller
DC controller

PCB

Check to ensure the paper feeder is latched in
place, and the self docking connector is not
damaged.

Check the connections on the DC controller PCB
connector J112 and mechanical controller PCB
connector J2007. Replace and check as follows:

1. Mechanical controller PCB.

2. DC controller PCB. see “DC Controller Board
Information” on page 2- 2.

Error (147) Engine Board IC Failure

FRU Action

1 DC controller

PCB

Replace the DC controller PCB, see “DC Controller
Board Information” on page 2-2.

Diagnostic Information 2-27

Error (148) Developer Unit Rotation Failure

FRU Action

1Poor

connection

2 Door switch Turn the machine off and disconnect the power cord.

3 Developing

rotary brake
clutch

Developing unit
drive clut ch

Mechanical
controller PCB

Developing unit
motor

Mechanical
controller PCB

Check the connection on the mechanical controller
PCB connector J2016. Reconnect it.

Disconnect co nnector J7 fro m the powe r supply unit.
When you tur n the door switch (SW2) ON, is there
continuity bet ween c onnec tors J7-1 (+24 VB) and J7 ­2 (+24VA)? Replace the door switch.

Watch the developer unit motor during POST. Does
it rotate? If yes, replace and check as follows:

1. Developing rotary brake clutch.

2. Developing unit drive clutch.

3. Mechanical controller PCB.

If no, replace and check as follows:

1. Developing unit motor.

2. Mechanical controller PCB.

4 Developing

rotary position
sensor

Mechanical
controller PCB

Check the c onnections on the mechanical controller
PCB connector J2006 and developing rotary
position s ensor co nnector J 60. Cl ean the sensor. If it
is not possible to clean it, replace and check as
follows:

1. Developing rotary position sensor.

2. Mechanical controller PCB.

2-28

Error (149) Developer Unit Pressure Failure

FRU Action

1Poor

connection

2 Door switch Turn the machine off and disconnect the power cord.

3 Developing unit Watch the developer unit motor during POST. Does

4 Developing

rotary position
sensor

Toner cartridge
position sensor

Mechanical
controller PCB

Check the connection on the mechanical controller
PCB connector J2016.

Disconnect co nnector J7 from the power s upply unit.
When you tur n the door switch (SW2) ON, is there
continuity betw ee n connec tors J7- 1 (+24VB) and J7­2 (+24VA)? Replace the door switch.

the developing unit motor rotate? Replace and
check as follows:

1. Developing unit motor.

2. Mechanical controller PCB.

Check the co nnections on the mechanical co ntro lle r
PCB connector J2006, toner cartridge position
sensor connec tor J59 and de vel oping rotary position
sensor position sensor J60. Replace and check as
follows:

1. Toner cartridge position sensor.

2. Developing rotary position sensor.

3. Mechanical controller PCB.

Error (152) Tray 2 Power Failure

FRU Action

1Poor

connection

2 Power supply

unit
Paper feeder
driver PCB
Mechanical
controller PCB
DC controller
PCB

Check the connections on the paper feeder driver
PCB connector J355 and power supply unit
connector J361. Reco nnect them.

Replace the paper feeder power supply unit.
Replace and check as follows:

1. Paper feeder driver PCB.

2. Mechanical controller PCB.

If the problem remains, replace the DC controller
PCB.
See “DC Controller Board Information” on page 2-2.

Diagnostic Information 2-29

No AC Power/Dead Machine

FRU Action

1On/Off switch

connector

2 Power supply Check voltage at the outlet. Inform the user that

3 Power cord Is the power cord firmly plugged into the printer, the

4 Circui t breaker

(CB1)

5 Wiring, power

supply unit

Be sure connec tor J6, see “Co nnector Locati ons” on
page 5-15, is connected into the LVPS. Thi s
connector will sometimes fall off the LVPS when
working in this area.

rated voltage is not supplied at the outlet.

paper feeder and the outlet? Replug it.
Is the circui t b reaker OFF? Press the b utto n to res et

the breaker. If the circuit breaker turns OFF again
immediately after turning the power switch ON,
check whether the AC power supply line is shorted.

Note:

LVPS, directly above the power cord connector. The
button can be viewed without removing the power
supply from the machine. Look in the lowest hole
toward the front of the machine. This hole is oblong.

Unplug the power cord. Check the continuity of the
ON/Off switch. Check the AC line wiring. Replace
the power su ppl y unit .

This circuit breaker, labeled CB1 is in the

2-30

No DC Power

FRU Action

1AC power

supply

2Wiring

DC load

3Fuse

Power supply
unit

Unplug the power cable. Is AC power being supplied
to this cable? Check AC power.

Turn the power switch OFF, and disconnect
connecto rs J3, J4, an d J5. Plug in the power cable,
and turn the power switch ON. Are the above
mentioned power supply unit connectors correctly
outputting DC power? Take care not to cause a
short. Turn the power switch OFF, connect 1 of the
disconnected connectors, and turn the power switch
ON. Repeat this for all the connectors, and
investigate the connector operating the protection
circuit, checking the wiring from that connector and
the DC load.

Is the power supply unit fuse blown? Replace the
fuse. Replace the power supply unit.

No Pickup (Manual Feed)

FRU Action

1 Gear Is the pickup motor drive properly transmitted by the

gears? Check the gears, and replace any damaged
ones.

2 Pickup motor

Pickup PCB

3 Pickup PCB

Manual feed
solenoid

Does the pickup motor rotate?
Check the connection of pickup PCB connector

J304, and if it is normal:
Replace the pickup motor.
Replace the pickup PCB.

Turn the power switch OFF, remove the pickup unit,
and disconnect the connector J33. Measure the
resistance between cable connectors J33-1 and
J33-2. Is it about 100 Ohms? If yes, replace the
pickup PCB. If no, replace the manual feed solenoid.

Diagnostic Information 2-31

No Pickup (Cassette Feed)

FRU Action

1 Gear Is the pic kup motor drive properly tra ns mi tted by the

gears? Check the gears, and replace any damaged
ones.

2 Pickup motor

Pickup PCB

3 Pickup PCB

Cassette feed
solenoid

Does the pickup motor rotate?

1. Check the connection of pickup PCB connector
J304, and if it is normal replace the pickup motor.

2. Replace the pickup PCB.

Turn the power switch OFF, remove the pickup unit,
and disconnect pickup PCB connector J303.
Measure the resistance between cable connectors
J303-1 and J303-2. Is it about 100 Ohms?

If yes, replace the pickup PCB.
If no, replace the cassette feed solenoid.

No Pickup (Optional Paper Feeder Pickup)

FRU Action

1 Gear train Is the paper feeder motor drive properly transmitted

2

Paper feeder
motor

Paper feeder
driver PCB

3 Paper feeder

driver PCB
Cassette feed

solenoid

2-32

by the gears? Check the gears, and replace any
damaged ones.

Does the paper feeder motor rotate?
Check the connection of paper feeder driver PCB

connector J353, and if it is normal replace the paper
feeder mo tor.

Replace the feeder driver PCB.
Turn the power switch OFF, remove the paper

feeder, and disconnect J354. Measure the
resistance between cable connectors J354-1 and
J354-2. Is it about 130 Ohms? If yes, replace the
paper feeder driver PCB. If no, replace the cassette
feed solenoid.

Registration Roller Does Not Rotate

FRU Action

1 Gear train Is the pickup motor drive properly transmitted by the

gears? Check the gears, and replace any damaged
ones.

2 Pickup PCB

Registration
roller clutch

Turn the power switch OFF, remove the pickup unit,
and disconnect the connector J34. Measure the
resistance between cable connectors J34-1 and
J34-2. Is it about 145 Ohms?
If yes, repl ace the pickup PCB.
If no, replace the registration roller clutch.

High-Voltage Power Supply Output

FRU Action

1 High voltage

contacts

2 High-voltage

power supply
PCB

Mechanical
controller PCB

DC controller
PCB

Are the high-voltage contact terminals soiled or
burnt? Clean the high-voltage contacts.

Does the trouble disappear when you replace the
high-voltage power supply PCB? Replace the high­voltage po wer s upply PCB . If not, repla ce an d che c k
as follows:

1. Mechanical controller PCB.

2. DC controller PCB, see “DC Controller Board
Information” on page 2- 2.

Diagnostic Information 2-33

Pickup / Feed System Theory

When the /PRNT signal is sent to the DC controller by the video
controller and the scanner motor is put in the READY state, the DC
controller issues the print sequence command to the mechanical
controller, which then starts printing. After a sheet of paper is picked
up by the cassette pickup roller or the manual feeding pickup roller, it
is fed by the feed rollers. Any skew of the paper is corrected by the
registration roller and it stops at the leading edge detection position.
The temporarily stopped paper is fed so that its leading edge will
match the gripper on the transfer drum as well as the leading edge
of the image on the photosensitive drum. Subsequently, the paper
passes through the transfer, separation, fuser, and delivery units to
the face-down or face-up tray.

2-34

The paper feed route can be divided into 3 sections:

1. Pickup unit,

2. Transfer drum unit,

3. Fusing/delivery unit.

Diagnostic Information 2-35

OHP Sheet Detection (transparency)

When an OHP sheet is used for this printer, the dedicated one must
be used with a white band at its leading edge. The following
determinations are made by measuring the time period that light
emitted from the paper top sensor (PS303) is shielded by this band,
and whether it is:

•

The dedicated OHP sheet, any other OHP, or paper.

•

Placed with the proper side up.

•

Placed with the proper edge leading.

If any non-dedicated OHP sheet is used or the dedicated OHP sheet
is placed with the wrong side up or the wrong end leading, the
mechanical controller will notify the DC controller which will signify it
as a jam.

The white band disappears when heated in the fusing process.

2-36

Diagnostic Information 2-37

Paper Feed Troubleshooting

Pickup Unit

(Codes 20 - 21, Paper Jam)

FRU Action

1 Paper Is recommended paper being used? Advise

the customer to use recommended paper.

2 Paper Is the paper deformed with curls or waves?

Replace the paper. Advise the user on the
storage method.

3 Paper Did it occur in the manual feed unit? Check

from Step 8.

4 Paper Did it occur in the cassette feed unit? Check

from Step 11.

5 Registration Is the registration roller clutch operating

properly? Check the registration roller clutch.

6 Registration Is the registration roller worn, deformed or

soiled? Clean the roller if it is soiled. If worn
or deformed, replace appropriate parts.

7 Prism Is the paper top sensor prism soiled? Clean

it. Replace it if it cannot be cleaned or it is
flawed. If it is OK, replace the pickup PCB.

8 OHP sheet Is dedicated OHP sheet being used, and is it

loaded correctly? Advise the user to use
dedicated OHP she et, and to set it corr ect ly.

9 Excessive

paper in manual
feeding tray

10 Pickup roller

Faulty pickup

Is more paper in the m anu al f ee ding tra y than
prescribed? Advise the user not to put more
than the suggested amount of paper in the
tray.

Does the pickup roller rotate during printing?
If yes , rep la ce the pickup roller. If no, see “No

Pickup (Manual Feed)”
11 Cassette Is the cassette set properly? Set it properly.
12 Paper set

incorrectly

2-38

Is the paper correc tly set aga inst the ca ssette

claw? Set it correctly.

FRU Action

13 Paper Is the paper folded? Replace the paper.
14 Excessive

paper in
cassette

15 Cassette

pickup roller,
Separation
roller, Feed
roller , Faulty
pickup

Is more print paper in the cassette than
suggested? Advise the user not to put more
than the suggested amount of paper in the
cassette.

Is the cassette pickup roller, the separation
roller, or the feed roller worn or deformed? If
yes, replace the respective roller. If no, check
“No Picku p (Cassette Feed)” on page 2-32 or
“No Pickup (Optional Paper Feeder Pickup)”
on page 2-32.

Diagnostic Information 2-39

Transfer Drum Unit

(Codes 22 - 23, Paper Jam)

FRU Action
1 Gripper Is the gr ipper damaged? Replace the gripper.
2 Gripper Does the gripper properly open and hold the

paper? Check whether:

• The gri pper hold-down spring is deformed
or disconnected.

• The gri pper lever is bent.

• The operation of the gripper drive
mechanism within the transfer drum is
smooth.

• The gri pper solenoid connector is
disconnected or the solenoid is defective.

3 Attraction

sensor

4 Separation

sensor

5 Attraction roller If the attraction roller is worn or deformed,

6 Discharge roller If the discharge roller is worn or deformed,

7 High-voltage

contact

8 Spring (2 each) If the springs pressing the attraction roller or

9 Transfer sheet

High-voltage
power supply
PCB

Check for binds. Refer to “Transfer Drum” on
page 7-60, assembly 29-3.

Check for binds. Refer to “Transfer Drum” on
page 7-60, assembly 29-3.

replace the attraction roller.

replace the discharge roll er.
If the high-voltage contact of the attraction

roller or the discharge roller is soiled or burnt,
clean the high-voltage contact. Replace it if it
cannot be cleaned.

the discharge roller aga ins t the tr a nsfer drum
are stretched, o r m iss in g, r epl ac e th e re lati ve
spring.

If the transfer sheet is soiled or deformed,
replace the transfer sheet. If not, replace the
high-voltage power supply PCB.

CAUTION: Do not touch the sheet with
your bare hands

.

2-40

Fuser/Delivery Unit

(Code 25, Paper Jam)
Note: Printers and replacement FRUs may experience rough

handling during shipping, causing the exit sensor (PS9) to be
contaminated with oil. As this sensor operates “active low”, the oil
may defuse the IR beam enough to prevent correct operation.
Therefore, replace PS9.

Use of a spray contact cleaner in most instances will allow normal
functioning of the fuser sensors, which have been contaminated with
silicone oil. The only cleaner currently approved by Lexmark is CRC
brand industrial contact cleaner # 03130. In addition to the cautions
on the Material Safety Data Sheet (MSDS) label attached to the can,
observe the following guidelines:

•

When spraying either fuser sensor (PS9 or PS10), place a piece
of absorbent material below the sensor to catch the excess
spray.

•

Use the supplied nozzle and direct the spray into the small
apertures in the inside walls of the sensors.

•

Spray quickly (approximately 1 second applications).

This spray leaves no residue, contains no CFCs and is plastic safe.
Do Not use a substitute spray that has not been tested and is not
plastic safe.

Diagnostic Information 2-41

Fuser

FRU Action

1 Fuser roller

Drive unit

2 Fuser rollers Is the fuser upper roller or the fuser lower

3 Fuser entrance

guide

4 Nip width Is the fuser roller engagement correct?

5 Cleaning belt Is the cleaning belt being wound correctly?

6Fuser

separation
guide

7 Delivery paper

sensor lever

Do the fuser rollers rotate smoothly? Check
the fuser roller drive unit.

roller deformed or flawed? If yes, replace
them.

Is the entranc e g uid e s oi led ? Is th ere a gu ide
protrusion due to a flaw or toner adhesion?
Clean th e entrance guide.

Replace the fuser unit.

Check the fuser cleaner unit.
Is the fuser separation guide soiled? Or is

there a protrusion due to a flaw or toner
adhesion? Clean the guide.

Does the delivery paper sensor lever move
smoothly? Adjust it so that it moves smoothly.

8 Delivery paper

sensor (PS9)

9 Oil applying unit

Deliver y drive
unit

Does the delivery paper sensor operate
correctly? Replace the sensor.

Is the fuser delivery roller rotating smoothly?
Is the face-down delivery roller rotating
smoothly? If yes, check the operation of the
oil applying unit. If no, check the delivery
drive unit, and replace the damaged part.

2-42

Multi-Feed

FRU Action

1 Paper Is recommen ded pape r being u sed? Adv ise the user

to use recommended paper.

2 Location Does it occur in the manual feeding tray? Check

step 5. (Cassette, check step 4).

3 Cassette Is the print paper placed properly against the

cassette c law? Place the paper corr ectly.

4 Separation

roller
Spring(s) *

5 Separation pad

Spring
(see Chapter 7,
Asm 25-5)

Is the separation roller worn or deformed? If yes,
replace the separation roller. If no, replace the
spring(s) pulling the separation roller.

Is the separation pad surface worn? Replace the
separation pad. If no, replace the separation pad
spring.

* See “Cassette Paper Pickup Asm” on page 7-48, (Asm 24). These
springs are not referenced, but attach to the same plastic assembly
that reference number 7 uses.

Diagnostic Information 2-43

Wrinkles

FRU Action

1 Paper Is recommended pape r being used? Advise the user

to use recommended paper.

2 Paper Do the wrinkles disappear when you use new

paper? As the paper probab l y was mo ist, adv ise the
user on the correct storage method.

3 Pickup unit Open the front cover while the paper is between the

pickup and fuser units. Is the paper wrinkled? Or is
the paper being t ra nsported with a sk ew? Check the
pickup unit.

4 Paper guide Is toner or other foreign matter on the paper guide?

Clean the guide.

5 Fuser entrance

guide
Fuser unit

Is the fuser entrance guide soiled? Clean the guide.
If no, replace the fuser unit.

Leading-Edge Fold

FRU Action

1 Paper Is recommended pape r being used? Advise the user

to use recommended paper.

2 Paper Is the paper curled or otherwise d ef ormed? Repla ce

the paper. Advise the user on the correct storage
method.

3 Excessive

paper (manual)

Is more paper placed at the pickup slot than
suggested? Advise the user not to place more than
the suggested amount of paper.

4 Paper setting

(cassette)

5 Cassette claw Is the cassette claw deformed? Replace the

2-44

Is the paper set properly against the cassette claw?
Set the paper correctly.

cassette claw. If no, check the paper feed unit, and
replace any flawed or deformed parts.

Skewing

FRU Action

1 Paper Is recommen ded pape r being u sed? Adv ise the user

to use recommended paper.
2 Cassette Is the cassette set properly? Set it correctly.
3 Excessive

paper
(manual)

4 Paper setting

(cassette)

5 Paper setting Is the paper placed against the manual feeding tray

6 Cassette claw Is the cassette claw deformed? Replace the

7 Paper dus t,

trash
Registration

roller

Is more paper place at the pickup slot than

suggested? Adv ise the user not to set mo re than the

suggested amount of paper.

Is the paper set properly against the cassette? Set

the paper correctly.

abutment? Properly set the paper on the manual

feeding tray.

cassette claw.

Is paper dust or trash collected at the registration

roller or feed guide? Clean.

If no, replace the cassette paper assembly.

Diagnostic Information 2-45

Error Codes - 9XX

Error (900) Software Error

Description Action

1 This can occur when:

• The paper being fed is a
differen t size than se lected
by the Setup Menu.

• Turning the machine off
and failing to wait at least
10 seconds before
switching it back on.

Feed the correct size paper.
After turning the machine off, wait

at least 10 se conds bef or e tu rning
back on.

Before replacing the video
controller board, tur n the printer
off and firmly reseat the board.

Error (941) Service ROM SIMM

Description Action

1 Code/Font Replace the ROM SIMM.

Error (939, 942, 943, 944) Service RIP Board

Description Action

1 29K processor

failure

Error (945) Service RIP Board

Description Action

1 ASIC 1 failure Replace the Video Controller Board.

2-46

Replace the Video Controller Board.

Error (946) Service RIP Board

Description Action

1 ASIC 2 failure Replace the Video Controller Board.

Error (947) Service RIP Board

Description Action

1 ASIC 3 failure Replace the Video Controller Board.

Error (948) Service RIP Board

Description Action

1 Compress/

Decompress
failure

Replace the Video Controller Board.

Error (949) Service RIP Board

Description Action

1 Decompress

failure

Replace the Video Controller Board.

Diagnostic Information 2-47

Error (950) Service RIP Board

Description Action

1 SRAM failure Replace the Video Controller Board.

Error (953) Service RIP Board

Description Action

1 NVRAM failure Replace the Video Controller Board.

Error (955) Service Video RAM Error

Description Action

1 Video RAM

failure

Replace the Video Controller Board.

Error (956) Service L2 Cache Error

Description Action

1 L2 Cache error Replace the Video Controller Board.

Error (960) Service Memory Error

Description Action

1 Bad or missing

DRAM in the
base DRAM slot

2-48

Replace the base DRAM.

Error (961) Bad / Missing DRAM

Description Action

1 Bad or missing

DRAM in the
optional DRAM
slot

Replace the optional DRAM.

Error (970/979) INI Failure

Description Action

1 INA failure Replace INA.

Error (977) Service Network Board

Description Action

1 Bad network

board

This error message indicates a bad Network board
is installed in the Network board slot. The system
processor has detected that an INA board is
installe d but cannot establish communications with
it. The X after the Network Board will identify which
network board is having a problem. Network Board 1
alwa ys ref ers to the IN A board in the bot tom slot and
Network Board 2 always refers to the INA board in
the top slot.

Diagnostic Information 2-49

Print Quality

Before you perform the following service checks, do the following:

•

Be sure the paper or transparencies are the recommended
finish and weight. If the paper weight is incorrect (too stiff), it
may not provide 100% adhesion to the transfer drum. The
trailing edge will not be attracted to the drum and will “flap” on
each revolution causing blurs and smears at the bottom of the
page. This may eventually transfer stray toner on to the back or
front of the paper.

•

Be sure the printer and supplies are used in the proper
environmental range.

•

If in doubt about a printer driver or other customer application,
use the test prints described in the diagnostic aids.

•

Use the following start of call test to determine where the
symptom exists.

Cartridge End-of-Life

When printing a large number of pages with a low percentage of
color coverage, it is possible for the cartridge to wear out before
using all the toner. Regardless of the amount of toner used, the
internal rollers must make the same number of revolutions.
Maximum cartridge life is approximately 5500 pages. Depending on
color usage, it is possible to exceed this limit and still have a large
quantity of toner remaining in the cartridge. This condition will lead
to streaking and background, which will be covered elsewhere in this
service check.

Print Quality Start Of Call

Refer to the Density Adjustment Panel (DAP) section, see “Density
Adjustment Panel” on page 3-12. Run the following three tests
described on page 3-12. Each test will isolate different print quality
conditions as described. Before starting, be sure all color density
settings on the D AP are set to nominal.

2-50

This Page Left Blank Intentionally

Diagnostic Information 2-51

Gradation Test

This test shows the presence of horizontal voids. Do not confuse a
void (which is a missing laser scan line) with small horizontal
variations in density called “jitter”, (see example on following page).

•

If voids are present, go to “Horizontal Voids Service Check” on
page 2-67.

•

If severe “jitter” is visible, replace the affected cartridge,
(especially if the “jitter” is greater for one color).

•

If the “jitter” is consistent across all four colors, replace the
photoconductor.

Note: Some “jitter” normally occurs due to gear train vibrations.

2-52

Horizontal Variation (“Jitter”) Example

Diagnostic Information 2-53

Solid Color Test

This test indicates which cartridge(s) is/are contributing to
background problems. It also shows which of the four cartridges has
reached end-of-life. The test produces a solid band of each color,
approximately 2 1/4 inches (60 mm) long. Each color should be a
uniform color with no vertical streaks. If streaks are present, replace
the cartridge. Cartridges that streak contribute to background.

Solid White Test

This test shows the amount of background. Background is most
visible as a white border 5/16 inch (8 mm) from the top edge of the
paper. Background is possible in any color (or combination of
colors), although it appears gray to the naked eye. Although a worn
photoconductor contributes to background, background is primarily
due to a cartridge condition. Photoconductor scratches show as a
black vertical line.

2-54

Print Quality Troubleshooting

Background

Symptom:

A slight tint to the entire page starting approximately
8 mm from the top edge of the page. It may appear to be gray, but
could be any combination of primary colors.

Cause:

Cool, dry environments or used cartridges nearing end of life.

Resolution:

Increase environmental temperature and humidity. Replacing all four
toner cartridges reduces background, if they are nearing end of life.
Call your country support function for assistance prior to replacing
parts.

Black Horizontal Lines

Symptom:

Horizontal lines of any length and width across the page repeating at
129 mm intervals.

Cause:

Improper removal or installation of the photoconductor. The drum
release arm must be lowered prior to removal or installation of the
photoconductor.

Resolution:

Replace the photoconductor.

Diagnostic Information 2-55

Black Vertical Line s

Symptom:

Thin vertical black lines of any length, anywhere on the page.

Cause:

Worn out or damaged photoconductor. This may be caused by the
photoconductor reaching end-of-life or damage resulting from a
severe paper jam.

Resolution:

Replace the photoconductor. Do not use a used photoconductor for
diagnostic purposes. The printer determines photoconductor life by
its electrical characteristics. Swapping used photoconductors may
result in inaccurate photoconductor life, which may result in
customer dissatisfaction or a service call.

Blur at Bottom of Page

Symptom:

A horizontal defect approximately 17 mm from the bottom of the
page. This defect is composed of vertical streaks, smears or a blur.
In severe cases, there may also be a blur 17 mm from the top of the
page.

Cause:

Certain weight and composition papers (mostly cotton), are not
adhering to the transfer drum. This causes the trailing edge to “flap”,
contacting the developer roller in the cartridge or the
photoconductor.

Resolution:

Change paper types.

2-56

Laser Failures

Symptom:

Jagged test and edges or very fine horizontal lines the entire width
of the page. These may occur as blank lines (voids) or as any color.
Vertical print may be wavy (see following example).

Cause:

Contaminated (toner) beam detect mirror, or beam detect lens in the
printhead, causes the laser to loose sync or power aberration.

Resolution:

Disassemble the printhead and clean the beam detect lens inside
the printhead. Also clean the small (10 mm X 10 mm) beam detect
mirror, or replace the printhead.

Low Color Coverage or Usage

Note: The following is not a machine condition.
Symptom:

Vertical streaks on the page. See “Vertical Streaks” on page 2-60,
for more information.

Cause:

Extended printing using minimal color coverage. The internal
mechanisms in the cartridge wear out before the level of toner is
depleted.

Resolution:

Replace the cartridge.

Diagnostic Information 2-57

Oil Soaking

Symptom:

Certain printers may demonstrate a condition that makes the top
(leading) edge of the first page appear to have been dipped in oil.
This oil stain is not to be confused with random oil spots. The
soaking may be so small as to be unnoticeable, except in certain
areas across the leading edge of the page. It may be as severe as
covering the top 3/4 of the page. This occurs with printers that are
left idle for long periods wit h “Power Saver” off . The factory defau lt is
“Power Saver” ON, set for 30 minutes. This means that the printer
will enter power saver mode within 30 minutes after a job prints.
Some customers object to this feature, as it requires additional time
to heat the fuser prior to printing. This is minimized by setting power
saver to the maximum (120 minutes) before the printer cools down.

Resolution:

•

Scroll through the menus to “Advanced Setup”, then scroll
through to “Power Saver 2”.

•

Turn it ON (default OFF). “P ower Saver 2” works only with
‘Power Saver” ON. (default). “Power Saver 2” turns on the fuser
every 59 minutes, to keep it close to target temperature. This
time interval is not adjustable. Early levels of microcode do not
have this feature.

•

Call your country support function for assistance, prior to
replacing parts.

2-58

Random Oil Spots on Page

This condition usually occurs following a long idle period or power
saver mode.

Symptom:

Random oil spots on paper may cause customer complaints.

Cause:

•

F ail ure of machine to evenly dist ribute silicon oil over both f use r
rollers.

•

Oil dissolved in rubber silicon returning to surface.

•

Carry out of debris under lower doctor blade.

Resolution:

•

Advise the customer to use the fuser cleaning page, accessible
from the main menu. Note: This does not work coming out of
“Power Saver Mode”, it works only on power up.

•

If the customer prefers to use a “Power Saver Mode”, advise
them to use Power Saver 2 mode. This turns on the fuser every
hour.

•

Power Saver 2 does not operate unless Power Saver 1 is
enabled.

•

If maximum printer accessibility is an issue, set Power Saver 1
to 120 minutes.

Spew

See the “Toner Scattered Service Check” on page 2-71, for detailed
information regardi ng sp ew.

Diagnostic Information 2-59

Vertical Streaks

Note: Run the “Gradation Test” from the density adjustment panel.
Symptom:

Severe vertical voids in the text, or graphics, (see example on
following page). This may occur on a single color, e very color, or any
combination.

Cause:

Cartridge(s) nearing end-of-life. This condition can occur regardless
of the amount of toner remaining in the cartridge. For additional
information, see “Low Color Coverage or Usage” on page 2-57.

Resolution:

Replace the affected cartridge(s).

2-60

Vertical Streaks Example

Diagnostic Information 2-61

Print Quality Service Checks

Black Service Check

FRU Action

1 Photoconductor Replace the photoconductor. If problem remains,

check the primary charging contact spring, the
photoconductor contact, the primary charging
contact plate and spring.

3 High-voltage

cable / resistor

4 High-voltage

power supply
PCB,
Mechanical
controller PCB

Check the continuity between the photoconductor
drum contact and the high-voltage PCB J1004-3. It
should be approximately 9K ohms. Replace high­voltage cable or contact if necessary.

If the problem remains, check and replace as
necessary the high-volta ge power supply PCB or the
mechanical controller PCB.

Blank Page Service Check

FRU Action

1 Front cover

back panel

2 Laser beam

shutter, shutter
arm

Check the shutter open-close boss for damage,
replace the front cover back panel if necessary.

Check the shutter and the shutter arm for proper
operation, replace if necessary.

3 High-voltage

cable / resistor

4 High-voltage

power supply
PCB,
Mechanical
controller PCB

2-62

Check the continuity between the developing bias
contact plate and t he high-voltage PCB J1004-1. It
should be approximately 9K ohms. Replace high­voltage cable or contact if necessary.

Check the toner cartridge contact. If the problem
remains, check and replace as necessary the high­voltage power supply PCB or the mechanical
controller PCB.

FRU Action

5 Transfer Check to ensure the transfer drum is free to move

up during the print process. This can be done by
manually rotating the drum lift mechanism
(Asm 19-1).

Blank Spots Service Check

FRU Action

1 Paper Is recommended paper being used? Print with

recommended paper. If the outcome is good, ask

the user to use recommended paper.
2 Paper Is the paper damp? Replace the paper.
3 Toner cartridge Does it appear f or a sp ecifi c colo r only ? Repla ce the

toner cartridge of the color for which it appears.
4 Transf er sheet Check th e trans fer sheet f or d irt or damage. Replace

the transfer sheet.

Caution

hands.
5 Photoconductor Check the photoconductor for dirt or damage.

Replace the drum cartridge, but only if it is

damaged. Do not replace the drum as a

troubleshooting technique. If a defect is present on

the developer or primary charging roller, it will

repeat. Refer to the spacing table.

: Do not touch the transfer sheet with bare

Diagnostic Information 2-63

Color Aberration Service Check

FRU Action

1 Gripper

Gripper spring

2 Transfer sheet Is the transfer sheet gou ged or torn off? Replace th e

3Gear

Transfer Drum

Is the transfer drum gripper damaged or is the
gripper spring deformed? Replace the damaged
part.

transfer sheet.

Caution

hands.
Is the photoconductor drum gear or the transfer

drum gear worn or loose? Check for uniformity or
chattering of the transfer drum rotation.

: Do not touch the transfer sheet with bare

Dark Image Service Check

FRU Action

1 Density sensor

unit

Operate the density adjustment panel to adjust the
density. Clean the density sensor lens. If the
problem remains, replace the density sensor unit.

2 High-voltage

power supply
PCB,
Mechanical
controller PCB

Clean the transfer drum ground contact and the
photocon ductor contact. If the problem remains,
clean the primary charge contact. If the problem
remains, check and replace as necessary the high­voltage power supply PCB or the mechanical
controller PCB.

2-64

Dirt On Back Of Paper Service Check

FRU Action

1 Paper Paper must b e the corre ct weight , see “Print Quali ty”

on page 2-50.
2 Lower fuser

roller
Attraction roll
Discharge roll
Cleaning brush

3 Attraction roll

and springs
Discharge roll

and springs
High-voltage

contacts
Charge roll

spring

4 Feed guide

See “Spacing Table Service Check” on page 2-69 to

aid in diagnosing the dirty or fa ili ng FRU.

Check the cl eaning brush is not damaged and there

is no paper in the cleaning assembly.

Check the attraction and discharge roll for damage,

the high-voltage contacts for dir t or damage and the

attracti on and disc harge roll springs. Replace parts

as necessary.

Check both guides for dirt or obstructions.

Fuser entrance
guide

5 Cleaning brush

motor

Check the cleaning brush motor connector J55.

Check the resistance of the cleaning brush motor.

Rotate the brush and take several readings. The

resistance should be approximately 40 ohms. Be

sure the cleaning brush motor is cammed into the

transfer drum at the end of a print cycle an d tha t the

cleaning brush motor runs.

If the problem remains, replace the mechanical

controller PCB.

Diagnostic Information 2-65

Dirty Print Servi ce Check

FRU Action

1 Fuser cleaning

belt

2 Fuser upper

roller
Photoconductor
Toner cartridge
Attraction roller

3 Poor attraction/

discharge

4 Poor attraction/

discharge

5 Poor attraction/

discharge

6 Poor attraction/

discharge

7 Paper Paper must be the correct weight. Check for soiled

Check the cleaning belt for proper operation and
conditio n. Replace if necessary.

See “Spacing Table Service Check” on page 2-69 to
aid in diagnosing the dirty or failin g FRU.

Is recommended prin t paper being used ? Advise the
user to use recommended paper.

Is the attraction roller or the discharge roller
deformed or soiled? Replace the affected roller.

Is the high-voltage contact of the attraction roller or
the discharge roller soiled or burnt? Clean the
contact. Replace it if it cannot be cleaned.

Are the springs pressing the attraction roller or the
discharge roller aga inst the transf er drum stretc hed?
Replace the spri ng(s).

paper being used. Clean the feed guide or the fuser
entrance guide.

8 Paper path Check th e entire paper pa th f or pape r (espec ially the

photoconductor and cleaning brush assembly).

2-66

Distortion Service Check

FRU Action

1Poor

connection

2 Laser/scanner

unit
DC controller

PCB

Horizontal

FRU Action

1 Photoconductor

or
toner cartridge

Voids

Is the connection good between DC controller PCB

connector J208 and connectors J102, J110 and

J111?

Is the connection good between laser/scanner unit

and DC controller conne ctors J401, J402, J451 and

J701? Replace and check in the following order:

1 Laser/scanner unit

2 DC controller PCB, see “DC Controller Board

Information” on page 2-2.

Service Check

If a white horizontal line appears in a repeating

pattern, see “Spacing Table Service Chec k” on p age

2-69 and repair or replace the indicated part.
2 Laser /

Scanner unit

If a white horizonta l line appears ra ndomly, clean the

small 1/4 inch squ are (10 mm) beam detec t mirror in

the printhead, or replace the assembly.

Diagnostic Information 2-67