Lexmark W850n, W850dn Service Manual

Lexmark™ W850n and W850dn Printer

• Tabl e of cont e n t s

• Start diagnostics

Revision: January 7, 2010

4024-110

• Safet y and notices

• Trademarks

• Index

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

Edition: January 7, 2010 The following paragraph does not apply to any country where such provisions are inc onsistent 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; there fore, this statement ma y not apply to you.

This publication could include tec hnical inaccuraci es or typographical er rors. Changes are period ically made to the information herein; these changes wil l be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22X/002-1, 740 West New Circle Road, Lexington, Ken tucky 40550, USA, or e-mail at Service InfoAndTraining@Lexmark.com. Lex ma rk may use or distribute any of the information you supply in any way it believes appropriate wi thout incurring any obligation to you. You can pur chase additional copies of publicati ons related to thi s product by calling 1-800-553-9727. I n other countries, contact your point of purchase.

References i n this publicat ion to produc ts, programs, or services do not imply that the manuf acturer 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 t hat produ ct, pr ogra m, or serv ice may be used. Any funct ional ly equi valent pro duct, pr ogram, or servi ce that does not infringe any existing intellectual property right may be used instea d. Eval uation and verifi cation of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user’s respons ibility.

Lexmark and Lexmark with diamond design are trade ma rks of Lexmark Internat ional, Inc., registered in the United States and/or other coun tries.

MarkNet is a trademark of Lexmark International, Inc., registered in the United States and/ or other countries. PrintCryption™ is a trademark of Lexmark International, Inc. PCL® is a registered trademark of the Hewlett-Packard Company. All other trademarks are the property of their respective owners.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private ex pense.

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P/N 12G0036

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Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Lithium warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

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

About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Printer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Basic model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Configured model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Tools required for servi ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

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

Using service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Confirm the installa tion status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

POR sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Printer operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 3

Error code messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

200.00 Sensor (registration) off jam (too long) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

200.01 Sensor (registration) static on jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

201.00 Sensor (fuser exit) on jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

202.00 Sensor (fuser exit) off jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

202.01 Sensor (fuser exit) off (too short) jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

202.02 Sensor (fuser exit) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

203.00 Sensor (exit 2) on jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

203.01 Sensor (exit 2) off jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

241.00 Sensor (pre-feed) on jam (tray 1 feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

241.01 Sensor (registration) on jam (tray 1 feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

242.00 Sensor (pre-feed) on jam (tray 2 feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

242.01 Sensor (tray 2 feed-out) on jam (tray 2 feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

242.02 Sensor (registration) on jam (tray 2 feed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

242.03 Sensor (tray 2 feed-out) static jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

250.00 Sensor (registration) on jam (MPF pick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

900.XX RIP card assembly soft ware failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41

903.00 RAM read/write check failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

904.00 NVM data failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

905.00 NVM read/write cannot be executed failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

906.00 CPU power to access NVM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

907.00 RFID ASIC failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

908.00 PPM data failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

910.00 Transport motor stop failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

911.00 Transport motor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

912.00 PC cartridge unit motor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

913.00 Printhead assembly failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

914.00 Toner add motor assem bly failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

915.00 Fuser cooling fan failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

916.00 PC cartridge cooling fan failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49

918.00 Sensor (exit 1 media shift HP) failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

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920.00 Fuser unit assembly on time failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

921.00 Over heat temperature failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51

922.00 Center thermistor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5 2

923.00 Rear thermistor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 2

924.00 Pressure rol l thermistor failur e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

925.00 Fuser operating temperature failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53

927.00 PC cartridge RFID data write failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

928.00 PC cartridge RFID communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

929.00 Sensor (ATC) failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54

930.00 Laser power failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55

932.00 Toner cartridge RFID data write failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

933.00 Toner cartridge RFID communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

939.00 RIP card assembly comm unication failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

941.00 Media tray 1 lift up / no media tray failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

942.00 Media tray 2 lift up / no media tray failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

951.XX RIP card assembly NVRAM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60

953.XX Operator panel assembly NVRAM failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-61

955.XX RIP card assembly NAND CRC failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

956.00 RIP card assembly processor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

956.01 RIP card assembly processor over temperature failure . . . . . . . . . . . . . . . . . . . . . . . . .2-63

956.02 RIP card assembly cool ing fan failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-63

980.03 Exit interface card assembly communication failure . . . . . . . . . . . . . . . . . . . . . . . . . . .2-64

Media size mismatch in width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 6 4

No media in the select media tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -65

Paper is installed (short edge) in the media paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

PC cartridge end of life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-66

PC cartridge end of life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67

PC cartridge RFID failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-67

PC cartridge set failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

Printer front door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68

Printer left door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-69

Printer left lower door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70

Scheduled maintenance required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 7 0

Standard bin 1 full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-71

Standard bin 2 full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

Toner cartridge empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-72

Toner cartridge near empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 4

Toner cartridge failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-74

Toner cartridge RFID failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75

Toner cartridge set failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-75

Tray 1 media size failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-76

Tray 2 media size failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77

Tray 1 media size mismatch in length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-77

Tray 2 media size mismatch in length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79

Image quality trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-81

Troubleshooti ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-81

Image Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-82

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

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2

Entering Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Exiting Diagnostic s mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

MOTOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

PRINT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

HARDWARE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

DUPLEX TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

INPUT TRAY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

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OUTPUT BIN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

FINISHER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

BASE SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

DEVICE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

PRINTER SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

EXIT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Configuration menu (CONFIG MENU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Available menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Maintenance page count (Maint Cnt Value) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Maintenance page counter reset (Reset Maint Cnt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

REGISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Print quality pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

SIZE SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Env Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Jobs On Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Disk Encryption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Short Edge Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Tray Low Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Exit Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Analyzing the Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Driving force transmission path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Media transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Multi-purpose feeder (MPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Detecting media size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Transfer roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Printhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Electrical components and controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Media size control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Printhead control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Fuser control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Xerographic Process During a Print Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Safety system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Repeating defect s

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

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

Handling ESD-sensiti ve parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

Before starting service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Printer front left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Top rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Switch (printer front door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Operator panel assem bly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Table of contents v

4024-110

Printer front door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 8

Front door support strap and fr ont door magnetic catch removal . . . . . . . . . . . . . . . . . . . . . . . .4-9

Front inner cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Right upper cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Right lower cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Cable hookup door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1 3

Rear motor cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Rear lower cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Option hookup cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 1 6

Switch (media size) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Media feed unit assembly 1 removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -18

Media feed unit assembly 2 removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21

Media tray side guides removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Media tray end guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 2 7

Media tray lift gear group removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 9

Media feed lift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Tray lift coupling assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 3 1

Tray lift one way clutch / gear assem bly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32

Media feed unit drive gear - 13 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

Media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

Sensor (media level) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36

Sensor (media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37

Sensor (pre-feed) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38

Media feed unit drive gear - 28 / 21 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

Media feed unit drive gear - 29 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40

Feed roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42

Feed roll one way clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 3

Feed roll one way gear 22 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44

Separation roll one way friction clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Separation roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46

Pick roll idler gear 33 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 4 7

Pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48

Pick roll drive gear 25 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 9

Feed unit drive gear 27 tooth removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -50

MPF feed unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 1

MPF media out actuator and upper frame removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52

Sensor (MPF media out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4- 5 3

MPF transport pinch roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54

MPF rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55

MPF feed drive gear group removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-56

MPF pressure pad removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57

MPF transport roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-58

MPF pick solenoid / pick lever removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59

MPF feed shaft assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 6 0

MPF pick roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-61

MPF fold down tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62

Vertical drive gear assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

Switch (left lower door interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-65

Media transport roll assembly / gear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-66

Printer left lower door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67

Printer left lower pinch roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68

Left lower door handle assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-69

Transfer roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Printer left door suppo rt strap removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-71

Printer left door asse mbly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72

Switch (printer left door int erlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-73

Transfer roll guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-74

Printer left door asse mbly handle removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-75

Registrati on roll assem bly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 7 6

. . . .4- 7 0

vi Printer Servi ce Manual

4024-110

Registrati on clut ch assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77

Sensor (registration) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78

Transport clutch assem bly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Sensor (tray 2 feed-out) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

Switch (PC cartridge interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Sensor (humidity and temperature) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87

Sensor (RFID PC cartridge) and sensor (RFID toner cartridge) removal . . . . . . . . . . . . . . . . . . 4-92

Toner cartridge guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-93

Toner add motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95

Fuser cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-96

Printhead assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-97

PC cartridge cooling fan duct removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-99

PC cartridge cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-101

Sensor (fuser exit) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102

Fuser unit assembly rem oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-103

Exit 1 media shift assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104

Media shift motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-107

Sensor (exit 1 media shift) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-108

Sensor (exit 1 bin full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-109

Exit 1 media shift gear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110

Standard exit 1 top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-112

Exit 1 drive belt removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-113

Dual drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-114

High voltage power supply (HVPS) car d removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-115

Switch (main power) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-116

Exit interf ace card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-117

Printer engine card assem bly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119

Low voltage power supply (LVPS) card asse mbly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120

AC power input socket assembly remov al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-122

AC power input socket removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-123

Finisher AC output removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-124

Rear RIP card cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-125

RIP card assembly remova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-126

Component locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

Printer boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

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

Printer motors and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Printer switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Preventive mainte nan ce. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication spec if ications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

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

Assembly 1: Covers and operator panel (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

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

Assembly 3: Media feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Assembly 4: Media feed unit exploded (tray 1 and tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 5: Media tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 6: MPF unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 7: MPF unit feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 8: Left lower door and transpor t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

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Assembly 9: Left door and transfer roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

Assembly 10: Printer left door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Assembly 11: Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 12: Printhead, cartridge guides, and fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 13: Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 14: Standard Exit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 15: Dual unit drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 16: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 17: Electrical cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Assembly 18: Electrical cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Assembly 19: Electrical cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 20: Electrical cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

Assembly 21: Electrical cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 22: Power cords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Assembly 23: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

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

Part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5

viii Printer Service Manual

Notices

Laser no tice

The printer is certified in the U.S. to conform to the requi rements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming t o the requirements of IEC 60825-1.

Class I laser products are not consid ered to be hazardous. The printer contains in ter nally a Class IIIb (3b) laser that is nomin all y a 5 milliwatt ga ll ium arsenide laser operating in the wavelength region of 770-795 nanomet ers. 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 maint enance, or prescribed service condition.

Laser

Der Drucker erfüllt gemäß amt li cher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission ) 60825-1 gemäß amtlicher Best äti gung erfüllt.

4024-110

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet si ch ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstr ahlt. 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 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 conc ernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante rép ond aux normes IEC 60825-1 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 l aser de Classe IIIb (3b) (arséniure de gallium d’une pui ssance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 na nomètres. L’imprimante et son système laser so nt conçus pour impossible, dans des conditions normales d’utilisation, d’ent retien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supéri eurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampant e 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 certificat a negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti del la norma CEI 60825-1.

I prodotti laser di classe non sono consider at i pericol osi. La st ampant e contie ne al suo interno un laser d i 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 proget tati in modo tale che le persone a contatto con la stampante, dur ante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radi azioni laser superiori al livello della classe 1.

Notices ix

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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 su bcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interi or 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 ni ngún ti po de radiación láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuari o o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora e stá cer tific ada n os E.U.A . em conf ormidade com os r equisi tos da regu lamentaç ão DHHS 21 CFR Subcapítulo J para a Clas se I (1) de produt os laser . Em outr os locai s, est á cer tific ada co mo um produ to laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos lase r da Class e I não são cons id erados per igosos . Inte rnamen te, a impress ora contém um produ to laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 mill iwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impress ora laser foram concebidos de forma a nunca existir qualquer possiblid ade de acesso humano a radiação laser superior a um nível de Class e I durante a operação nor m al, 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 eis en vastgelegd in DHHS 21 CFR Subchapter J, voor ander e landen in IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voor zien 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 laser gedee lte en de print er zijn zo ontworp en dat bij normaal gebr uik, bi j onder houd of repar atie conform de voorschriften, nooit blootstelling mogelijk is aan laserstr aling boven een niveau zoals voorgeschr even is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der

nominelt er en 5 milli watt galliumarsen id l aser, som arbejder på bølgelæ ngdeområdet 770-795 nano me ter. Lasersystemet og printeren er udf ormet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved nor m al dr ift, brugervedl igeholdelse eller obligatoriske servicebetingelser.

x Printer Service Manual

Huomautu s las er laittees ta

Tämä kirjoi tin on Yh dysval loiss a luokan I (1) las erlai ttei den DHHS 21 CFR Subc hapt er J -määr ity ksen mukai nen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I laserlaitteiden ei kat sota olevan vaarallisia käyttäjälle. Kir joittimessa on sisäinen luokan IIIb (3b) 5 milliwatin gal liumarsenidil aser, joka toimii aaltoalueella 770 - 795 nanom etriä. Laserjärjestelmä ja kirjoit in on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voi ma kkaam m alle säteilylle kirjoittimen nor m aalin toiminnan, käyttäjän t ekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja su ojalu kitus ohitettae ssa olet altt iina näk ymät tömälle la sers äteilyl le. Älä katso sät eeref er ton.

VARNING! Osynlig laserst rålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

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

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gal lium-arsenid på 5 mil li watt som arbetar i våglän gdsområdet 770-795 nanometer. Lasersystem et och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrå lning över Klass I-nivå vi d normal användning, underhåll som utförs av användaren eller annan föreskriv en serviceåtgärd.

4024-110

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underka pit tel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i I E C 60825-1.

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. Lasersystem et og skrive ren er utformet slik at personer aldri utsett es for la serstrål i ng ut over klasse I-n ivå under vanlig bruk, vedlikehold som utføre s av brukeren, eller foreskrevne serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certif icat als Estats Units, aquesta impressor a compleix els requi sits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en alt res llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.

Els productes l àser de classe I no es considere n peri llosos. Aquesta impr essora conté un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funci ona a la regió de longitud d’ona de 770-795 nanòmetres. El si stema làser i la impressora han sigut concebuts de manera que mai hi hagi exposici ó a la radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tas ques de m anteniment d’usuari ni durant el s serveis que satisfacin les condicions prescrites.

Notices xi

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xii Pr inter Service Manual

Lithium warn ing

CAUTION—POTENTIAL INJURY:

There is a danger of explosion if a lithium battery is incorrectly replaced. Replace i t onl y wit h the same or an equiv alent t ype of l ithi um batte ry. Do not recharg e, disa ssembl e, or i nciner ate a lithium batte ry. Discar d used batter ies according t o the manufact urer’s i nstructions and local regulations.

Safety information

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

components. The man ufacturer is not responsible for safety in the event of use of unauthorized replacement parts.

• The maintenance inf ormation for this product has been prepared for use by a profe ssional 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.

• CAUTION: When you see this symbol, there i s a danger from hazardous volta ge i n the area of the

product where you a re work ing. Unp lug th e product be fore y ou begin, or us e cau tion i f th e product must receive power in order to perform the task.

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Consignes de sécurit é

• La sécurité de ce pro duit repose sur des tests et des

agréations por tant sur sa conception d'origine et sur des composants particulier s. Le fabricant n'assum e aucune respon sabilité concernant la sécurité en cas d'ut ilisation de pièces de rechange non agréées.

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

maintenance qualifié.

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

d'entretien qualifié devra prendre toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du

produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou fai tes preuve de vigilance si l' exécution de la tâche exige que le produit reste sous tension.

Norme di sicurezza

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

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

• Le informazion i riguardanti la manutenzione di questo prodot to 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 autorizzat o deve, quindi, adottare le precauzioni necessarie.

• ATTENZIONE: Questo simbolo indi ca la presenza di tensione pericolosa nell'area del prodotto.

Scollegare il pr odotto prima di iniziar e o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.

Lithium warning xiii

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Sicherheitshinweise

• Die Sicherheit di eses Produkts basiert auf Test s und Zulassungen des ursprünglichen Modells und

bestimmter Baut eil e. Bei Verwendung nicht gene hm igt er Ersatzteile wird vom Her steller keine Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für diese s Produkt sind ausschließlich für die Verwendung durch ei nen

Wartungsfachmann bestimmt.

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

elektrischen Schlags und körperlicher Verletzung . Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektri sche Spannung hin, die in diesem

Bereich des Produkts auf tret en kann. Zieh en Sie vor den Arbeit en am Gerät den Netzsteck er des Geräts, bzw. arbeiten Sie mit große r Vor sicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

Pautas de Seguridad

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

específico s. El fabri cante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.

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

cualificado de mantenimiento.

• Existe mayor riesgo de de scarga e léc trica y de dañ os pe rsonal es du rante e l desmont aj e y la r eparaci ón de

la máquina. El personal cualificado debe ser consciente de est e peli gro y tomar las precauciones necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que est á

trabajando es peligroso. Antes de empezar, desenchufe el equipo otenga cuidado si, para trabajar con él, debe conectarlo.

Inform a çõ es de Segura nça

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

específico s. O fabr icante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas.

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

devem ser utilizadas por outras pessoas.

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

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

• CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão

perigosa na zona do produto em que está a trabalhar . Ant es de com eçar, desligue o produto da tomada eléctr ica ou seja cu ida doso caso o pr oduto t enha de estar liga do à c orrent e eléc tric a para realizar a taref a necessária.

xiv Printer Service Manual

Informació de Seguretat

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

específics . El fabricant no es fa responsable de les qüestions de seguretat si s'u ti litzen peces de recanvi no autoritzades.

• La informació pel ma nteniment d’aquest pr oducte 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 con venients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu

treballan t és perill ós. Abans de començ ar, desendol leu l' equip oextremeu les precaucion s si, per treballar am b l'equip, l'heu de connectar.

4024-110

Safety in fo rmation xv

4024-110

CAUTION—POTENTIAL INJURY:

A caution identifies something that might cause a servicer harm.

CAUTION—SHOCK HAZARD:

This type of caution i ndicates there is a danger from hazardous voltage in t he area of the product where you are working. Unplug the product befor e you begin, or use caution if the product must recei ve power in order to perform the tas k.

CAUTION—HOT SURFACE:

This type of caution i ndicates a hot surface.

CAUTION—TIPPING HAZARD:

This type of caution i ndicates a tipping hazard.

Preface

The service information for the Lexmark W850 i s contained within three ser vice manuals:

• Printer Service Manu al—Contains the base printer service information includin g the opt ions and finisher

error codes and tests.

• Options Service Man ual— Contains specific inf ormation for the 2X 500-Sheet Drawer (2TM), 2000-Sheet

Dual Input (TTM), Duple x, Hi gh Capacity Feeder and Exit 2 options and a list of error codes and tests.

• Finisher Service Manual—Contains specifi c information for the Finisher option, list of error codes and

tests.

The printer service manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General infor m a ti o n contains a general description of the printer and the maintenance approach used to

repair it. Special tools and test equipment are required, as well as general environmental and safety instructions.

2. Diagnostic informati on contains an error indicator tab le, symptom tables, and service checks used to

isolate failing field replaceable units (FRUs).

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

4. Repair infor ma t io n provides instructions for making printer adjustments and removing and inst alling

FRUs.

5. Component locations uses illustrations to identify the component locations and test points on the printer.

6. Preventive maintenance contains the lubrication specif ications and recommendations to prevent

problems.

7. Parts catalog cont ains illustrations and part numbers for individual FRUs.

Conventions

Note: A note provides additional information. Warning: A warning identi fi es something that might damage the product hardware or soft ware.

There are several types of caution statements:

xvi Printer Service Manual

1. General in formation

Standard output bin

Operator panel

Tray 1 and Tray 2 (500-sheet trays)

Multipurpose feeder (MPF)

About this manual

This manual is a stand ard service manual containing information required for maintenanc e of the Lexmark™ W850n and W850dn (4024-110) laser printers.

Printer overview

CAUTION: Do not set up this product or make any electrical or cabling connections, such as the power cord or

options and features, during a lightning storm.

Basic model

The following illustration shows a printer with its base features.

4024-110

General information 1-1

4024-110

Exit 2* (Used in conjunction with duplex unit)

Bridge unit* (Used in conjunction with finisher)

Finisher*

Operator panel

Tray 3 and Tray 4* (500-sheet trays or 850- and 1150-sheet dual input trays)

Tray 1 and Tray 2 (500-sheet trays)

Tray 5* (2000-sheet high capacity feeder) (HCF)

Multipurpose feeder (MPF)

Duplex unit*

Configured model

The following illustration shows a fully configured printer. Items denoted w ith an asterisk (*) are options.

Tools required for service

1-2 Printer Service Manual

Flat-blade screwdriver #1 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic #2 Phillips screwdriver, magnetic short-blade Needle nose pliers Diagonal side cutters Spring hook Analog or di gital multi meter Parallel wrap plug 1319128 Twinax/serial debug cable (#1381963) Coax/serial debug cable (#1381964)

5.5 mm hexdriver (magnetic)

Acronyms

2TM 2 Tray Module AC Alternate Current ASIC Application Speci fic Integrated Circuit CRU Customer Replaceabl e Unit CSU Customer Setup DC Direct Cur rent DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory EDO Enhanced Data Out EP Electrophotographic Process ESD Electrostati c Discharge FRU Field Replaceable Unit GB Gigabyte GFI Ground Fault I nterrupter HCF High-Capacity Feeder HVPS High Voltage Power Supply LASER Light Amplificatio n by Stimu lated Emission of Radiation LCD Liquid Crystal Display LD Laser Diode LED Light-Emitting Diode LEF Long Edge Feed LVPS Low Voltage Power Supply MPF Multi-Purpose Feeder MS Microswitch NVM Nonvol atile Memory NVRAM Nonvolatile Random Access M em ory OEM Original Equipment Manufacturer OPT Optical Sensor PC Photoconductor PEL Pictur e element POR Power-on Reset POST Power-on Self Test PPM Pages Per Minute PSC Parallel Synchronous Communications PSD Position Sensing Device PWM Pulse Width Modulation RFID Radio Frequency Identification RIP Raster Imaging Processor ROM Read only Memory RPM Revol utions Per Minute SDRAM Synchr onous Dual Random Access Memory SEF Short Edge Feed SIMM Single Inline Memory M odule SOS Start of scan SRAM Static Random Access Memory TVOC Total Volatile Organic Compound TTM Tandem Tra y Module UPR Used Parts Return VVolts V ac Volts alternating current V dc Volts direct current

4024-110

General information 1-3

4024-110

1-4 Printer Service Manual

2. Diagnostic information

CAUTION—SHOCK HAZARD:

Remove the power cord from the electrical outlet and th en fr om the printer before conne cting or disconnecting any cable, assembly, or electronic board. This is a precaution for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/ peripherals.

CAUTION—POTENTIAL INJURY:

The printer weighs approximately 41 kg (90.2 lbs) and requires two or more trained personnel to lift it safely. Make sur e your fingers are not under the printer when you lift or set t he pri nter down.

CAUTION—SHOCK HAZARD:

If the printer is kept on, never touch the conductive parts while it is not speci fically required. The power switch and inlet of the low voltage power supply card (LVPS card) assembly is live even while the power supply is cut off . Never touch the live parts.

CAUTION—HOT SURFACE:

The inside of the printer might be hot. To reduce the risk of injury from a hot compo nent, allow th e surface to cool before t ouching.

Start

4024-110

Warning: When operating the driving units usi ng the di agnos tics or other tools , be sure to kee p them cove red

unless otherwi se specified.

Warning: When operating the driving units using the diagnostics or other tools, never t ouch the driving units.

When operating the dr iving units using diagnostics or other tools , be sure to follow the procedures in this manual.

Warning: Servicers should wear a wrist band or the li ke to remove st atic el ectrici ty fr om their bod y, groundi ng

their body while work ing. Go to “Handling ESD-sensitive parts” on page 4-1.

Using service checks

To determine the cor rective action nece ssary to repair a printer, look for the following information:

• Verify the installation status. G o to “Confirm the installation status” on page 2-2.

• Does POR (power on reset) stop? Check the POR sequence. Go to “POR sequence” on page 2-2.

• If you get an error code message, go to “Error code m essages” on page 2-5. – For detailed informati on on specific error codes and error messages, go to “” on page 2-22.

• If you have an attenda nce m essages, refer to the User’s Guide.

• Additional operator panel information, go to “Printer operator panel” on page 2-3.

Note: There may be print er error messages that are not contained in this service manual. Call your next level

support for ass istance.

Diagnostic information 2-1

4024-110

Confirm the installation status

Be sure to check the following items before starting the troubl eshooting procedures.

• With the power co rd un plugged f rom the wal l out let, check th at the co rd is f re e from bre akage, sh ort-c ircui t,

disconnected wire, or incorrect connection in the power cord.

• The printer is properly grounded. Check t he power cord ground terminal.

• The printer is no t inst alle d at a plac e subjec ted to extr eme temp erature, e xtrem e humidi ty or r apid chan ges

in temperatur e.

• The printer is not i nstalled close to water service, humidifier, heat generatin g unit , fire, in a very dusty

place, or a place exposed to air flow from the air conditioning system.

• The printer is not installed in a place where volat ile gas or inflammable gas is generated.

• The printer is not i nstalled in direct sun.

• The printer is inst alled on a level and stable surface.

• Media meets specifications and is installed properly.

• Customer maintenance parts have been replaced at the specified intervals.

• Check all attached options for proper attachment and electrical connection.

• Refer to th e User’s Guide for proper installation.

POR sequence

The following is an example of the events that occur dur ing the POR sequence for the base machine with no media handling opt ions installed.

1. Power the machine on.

2. The RIP card assembly cooling fan turns on.

3. Oper ator panel LED becomes solid.

4. While loading code, a ser ies of dots scroll across the screen.

5. The transport m o to r tur n s o n.

6. The fuser unit assembly lamps turn on.

7. The fuser cooling fan turns on.

8. The following is an example of the screen that displays after the code is loaded.

256 MB 800 Mhz 256 MB = Amount of memory 800 Mhz = Processor speed

9. An anim ated stopwatch appears on the screen.

10. Ready appears on the screen.

2-2 Printer Service Manual

Prin ter operator p anel

123

456

789

Back

Display

Indicator

light

Numeric keypad

Select buttonNavigation buttonMenu Stop

USB direct interface

123

456

78 9

The printer operator panel consists of the se it em s:

• A four-l ine, backlit, gray-scale display that can show both graphics and test

• Eight but tons

• Indicator light

• Numeric pad

• USB direct interface

The use of the buttons and the layout of the display panel is described in the following table.

4024-110

Item Description

Display Shows messages that communicate the status of t he printer Indicator lig h t • Off—The power is off.

• Blinking green—The printer is warming up, processing data, or printing.

• Solid green—The printer is on, but idle.

• Solid red—Operator intervention is needed.

Numeric keypad Enter numbers or symbols on the display.

Select • Opens a menu item and displays the available values or settings.

• Saves a displayed menu item as the new user default setting.

Notes:

• When a new setting is saved as the user default setti ng, it remains in effect until a new setting is saved or until factory defaults are restored.

• Settings chosen from a softwa re progr am can also ch ange o r overr ide t he user default settings selected from the printer control panel.

Diagnostic information 2-3

4024-110

Item Description

Navigation Press the up or down ar row buttons to scroll through menus or menu items, or to

increase or decr ease a value when entering numbers. Press the left or right arrow buttons to scroll through menu settings (also called

values or optio ns), or to scroll through text that rolls to another screen.

Stop Stops all printer activity

A list of options is offered once Stopped appears on the display .

Menu Opens the menu index

Note: The menus are available only when the pri nter is in the Ready state.

Back Returns the display to the previous screen

USB direct interface Insert a flash dri ve into the front of the printer to print saved files .

Note: Only the front USB direct interface supports flash drives.

2-4 Printer Service Manual

Error code messages

4024-110

Error code o r

message

200.00 Paper jam Check area A

200.01 Paper jam Check area A

201.00 Paper jam Check area A

202.00 Paper jam Check area A

202.01 Paper jam Check area A

Error con tents Description/Action

Sensor (registration) off jam (too long)

Sensor (registration) static jam

Sensor (fuser exit) on jam The sensor (fuser exit) is not turned on within the

Sensor (fuser exit) off jam The sensor (fuser exit) is not turned off within the

Sensor (fuser exit) off (too short) jam

The sensor (regi stration) is not turned off within the specified time after the registration clutch is turned on.

Go to “200.00 Sensor (registration) of f jam (too

long)” on page 2-23.

Media remains on the sensor (registrati on). Go to “200.01 Sensor (registration) st atic on

jam” on page 2-24.

specified time after the registration clutch is turned on.

Go to “201.00 Sensor (fuser exit) on jam” on

page 2-24.

specified time after the sensor (fuser exit) is t urned on.

Go to “202.00 Sensor (fuser exit) off jam” on

page 2-26.

The sensor (fuser exit) is turned off earlier than the specified time after the sensor (fuser exit) is t urned on.

Go to “202.01 Sensor (fuser exit) off (too short)

jam” on page 2-27.

202.02 Paper jam Check area A

203.00 Paper jam Check area A

203.01 Paper jam Check areas

A, E

203.02 Jam in A

203.03 Jam in A, E

Sensor (fuser exit) static jam Media remains on the sensor (fuser exit).

Go to “202.02 Sensor (fuser exit) static jam” on

page 2-28.

Sensor (exit 2) on jam The senso r (exit 2) is not turned on within the

Sensor (exit 2) off jam The sensor (exit 2) is not turned off within the

Sensor (exit 2) is on the standard bin or simp lex finisher

Sensor (exit2) stat ic jam Media remains on the sensor (exit2).

specified time after the sensor (fuser exit) is t urned on.

Go to “203.00 Sensor (exit 2) on jam” on

page 2-28.

specified time after the sensor (exit 2) is turned on. Go to “203.01 Sensor (exit 2) off jam” on

page 2-30.

The sensor ( exi t 2) was tur ned on when t he media i s delivered to the exit 1 standard bin or simplex finisher.

Refer to Options Service Manual.

Diagnostic information 2-5

4024-110

Error code o r

message

230.00 Paper jam Check areas

A, E

230.01 Paper jam Check area D

231.00 Paper jam Check areas

A, D

231.01 Paper jam Check areas A, D

241.00 Paper Jam Check area,

tray 1

Error con tents Description/Action

Sensor (duplex wait) on j am The sensor (duplex wait) is not turned on within the

sensor (duplex wait) static jam

Sensor (registration) on jam (duplex media feed)

Sensor (pre-feed) on j am (tray 1 feed)

specified time after the exit2 motor is turned on. Refer to Options Service Manual.

Media remains on the sensor (duplex wait). Refer to Options Service Manual.

Sensor (registration) is not turned on within the specified time after the duplex motor is turned on.

Refer to Options Service Manual.

Sensor (registration) is not turned on within the specified time after the sensor (duplex wait) is turned on.

Refer to Options Service Manual.

The sensor (pre- feed) tray 1 is not turned on within the specified ti m e after the tray 1 media feed lift motor is turned on.

Go to “241.00 Sensor (pre-feed) on jam (tray 1

feed)” on page 2-32.

241.01 Paper jam Check areas

A, tray 1

242.00 Paper jam Check area

tray 2

242.01 Paper jam Check area B,

tray 2

242.02 Paper jam Check area B

242.03 Paper jam Check area B

243.00 Paper jam Check area 3

Sensor (registration) on jam (tray 1 feed)

Sensor (pre-feed) on j am (tray 2 feed)

Sensor (tray 2 feed-out) on jam (tray 2 feed)

Sensor (registration) on jam (tray 2 feed)

Sensor (tray 2 feed-out) static jam

Sensor (pre-feed) on j am (tray 3 media feed)

The sensor (regi stration) is not turned on within the specified time after the sensor (pre-feed) media feed unit 1 is turned on.

Go to “241.01 S ensor ( regist ration ) on j am ( tray 1

feed)” on page 2-33.

The sensor (pre- feed) tray 2 is not turned on within the specified ti m e after the tray 2 media feed lift motor is turned on.

Go to “242.00 Sensor (pre-feed) on jam (tray 2

feed)” on page 2-34.

The sensor (tra y 2 feed-out) is not turned on within the specified ti m e after the sensor (pre-feed) media feed unit 2 is turned on.

Go to “242.01 Sensor (tray 2 feed-out) on jam

(tray 2 feed)” on page 2-36.

The sensor (regi stration) is not turned on within the specified time after the sensor (tray 2 feed-out) i s turned on.

Go to “242 .02 Sensor (regi stration ) on jam (tray 2

feed)” on page 2-38.

Medi a remains on the se ns or (tray 2 feed- o ut). Go to “242 .03 Sensor (tra y 2 feed-out) stati c jam”

on page 2-39.

The sensor (pre- feed) is not turned on within the specified time after the tray 3 feed lift motor is turned on.

Refer to Options Service Manual.

2-6 Printer Service Manual

4024-110

Error code o r

message

243.01 Paper jam Check areas

C, tray 3

243.02 Paper jam Check areas

A, B

243.03 Paper jam Check area B

243.04 Paper jam Check area C

244.00 Paper jam Check areas

C, tray 4

Error con tents Description/Action

Sensor (tray 3 feed-out) on jam (tray 3 media feed)

The sensor (tray 3 feed-out) is not tur ned on within the specified ti m e after the pre-feed sen sor3 is on.

Refer to Options Service Manual.

Sensor (tray 2 feed-out) on jam (tray 3 media feed)

The sensor (tray 2 feed-out) is not tur ned on within the specified ti m e after the sensor (tray 3 feed-out) is turned on.

Refer to Options Service Manual.

Sensor (registration) on jam (tray 3 media feed)

The sensor (regi stration) is not turned on within the specified time after the sensor (tray 3 feed-out) i s turned on.

Refer to Options Service Manual.

Sensor (tray 3 fe ed-out) stati c jam

Sensor (tray 4 feed-out) on jam (tray 4 media feed)

Media remains on the sensor (tray 3 feed-ou t). Refer to Options Service Manual.

The sensor (tray 4 feed-out) is not tur ned on within the specified ti m e after the sensor (pre-feed) is turned on.

Refer to Options Service Manual.

244.01 Paper jam Check areas

C, tray 4

244.02 Paper jam Check areas

B, C

244.03 Paper jam Check area B

244.04 Paper jam Check area

tray 4

244.05 Paper jam Check areas

C, tray 4

245.00 Paper jam Check area K,

tray 5

Sensor (tray 3 feed-out) on jam (tray 4 media feed)

Sensor (tray 2 feed-out) on jam (tray 4 media feed)

Sensor (registration) on jam (tray 4 media feed)

Sensor (pre-feed) on j am (tray 4 media feed)

Sensor (tray 4 fe ed-out) stati c jam

Sensor (tray 5 feed-out) on jam

The sensor (tray 3 feed-out) is not tur ned on within the specified ti m e after the sensor (tray 4 feed-out) is turned on.

Refer to Options Service Manual.

The sensor (tray 2 feed-out) is not tur ned on within the specified ti m e after the sensor (tray 4 feed-out) is turned on.

Refer to Options Service Manual.

The sensor (regi stration) is not turned on within the specified time after the sensor (tray 4 feed-out) i s turned on.

Refer to Options Service Manual. The sensor (pre- feed) is not turned on within the

specified time after the tray 4 feed lift motor is turned on.

Refer to Options Service Manual.

Media remains on the sensor (tray 4 feed-ou t). Refer to Options Service Manual.

The sensor (tray 5 feed-out) is not tur ned on with in the specif ied time after the HCF feed lift motor is turned on.

Refer to Options Service Manual.

Diagnostic information 2-7

4024-110

Error code o r

message

245.01 Paper jam Check area K

245.02 Paper jam Check area B

245.03 Paper jam Check area K

250.00 Paper jam Check areas

A, MPF

280.00 Paper jam Check areas

Error con tents Description/Action

Sensor (tray 5 feed-out) on jam

Sensor (registration) on jam The sensor (r egistration) on the printe r i s not turned

Sensor (tray 5 fe ed-out) stati c jam.

Sensor (registration) on jam (MPF pick)

Sensor (bridge unit media entrance) on jam

The sensor (tray 5 feed-out) on the print e r i s not turned on within the specified time after the HCF feed lift motor is turned on.

Refer to Options Service Manual.

on within the specified time after the HCF feed lift motor is tur n ed o n.

Refer to Options Service Manual. Paper remains on the sensor (tray 5 feed-out).

Refer to Options Service Manual.

The sensor (regi stration) is not turned on within the specifie d time after the MPF pick solenoid is turned on.

Go to “250.00 Sensor (registration) on j am (MPF

pick)” on page 2-40.

Sensor (bri dge uni t m edia ent rance) is no t turned on within the specified time after the sens or (fuser exit ) in the printer i s tur ned on.

Refer to Finisher Servi ce Manual.

280.01 Paper jam Check area A

280.02 Paper jam Check area F

281.00 Paper jam Check area A

281.01 Paper jam Check area F

281.02 Paper jam Check area F

Sensor (bridge unit media entrance) Stati c jam A

Sensor (bridge unit media entrance) Stati c jam B

Sensor (bridge unit media exit) on jam A

Sensor (bridge unit media exit) on jam B

Sensor (bridge unit media exit) on jam C

Paper remains on the sensor (bridge unit me dia entrance).

Refer to Finisher Service Manual.

Paper remains on the sensor (bridge unit me dia entrance).

Refer to Finisher Service Manual.

Sensor (bri dge unit media exit) is not turned on within the specified ti me after the sensor (bridge unit media entrance) is turned on.

At this time, the sensor (fuser exit) in the print er is in the on state.

Refer to Finisher Service Manual. Sensor (bri dge unit media exit) is not turned on

within the specified ti me after the sensor (bridge unit media entrance) is turned on.

At this time, the sen sor (bridge unit media ent rance) is in the on state.

Refer to Finisher Service Manual. Sensor (bri dge unit media exit) is not turned on

within the specified ti me after the sensor (bridge unit media entrance) is turned on.

Refer to Finisher Service Manual.

281.03 Paper jam Check area F

2-8 Printer Service Manual

Sensor (bridge unit media exit) Static jam A

Paper remains on the sensor (bridge unit me dia exit).

Refer to Finisher Service Manual.

4024-110

Error code o r

message

282.00 Paper jam Check area F

282.01 Paper jam Check areas

283.00 Paper jam Check areas

G, G4

283.01 Paper jam Check area

283.02 Paper jam Check areas

G2, G3

Error con tents Description/Action

Sensor (finisher media entrance) on jam

Sensor (finisher media entrance) Stati c jam A

Sensor (buffer path) on jam A Sensor (buff er path) is not turned on within the

Sensor (buffer path) on jam B Sensor (buff er path) is not turned on within the

Sensor (buffer path) Static jam A

Sensor (finisher media entrance) is not turned on with the specifi ed ti m e aft er the sensor (bridge unit media exit) is tur ned on.

Refer to Finisher Service Manual. Paper remains on the sensor (finisher media

entrance). At this time, the sen sor (bridge unit media exit) i s

turned on. Refer to Finisher Service Manual.

specified time after the sensor (finisher media entrance is turned on.

Refer to Finisher Service Manual.

specifie d ti me after the sensor (finisher media exit) is turned on.

At this time, the sen sor (diverter gate) is tur ned on. Refer to Finisher Service Manual.

Paper remains on the sensor (finisher buffer path). At this time, both sensor (diverter gate) and sensor

(transpor t exi t) are on state. Refer to Finisher Service Manual.

283.03 Paper jam Check areas

283.04 Paper jam Check areas

284.00 Paper jam Check area F

284.01 Paper jam Check area F

Sensor (buffer path) Static jam B

Sensor (buffer path) Static jam C

Sensor (lower media exit ) off jam A

Sensor (lower media exit ) on jam A

Paper remains on the sensor (finisher buffer path). At this time, the se nsor (div erter gate) is on st at e but

the sensor (finisher media entrance) is turned off. Refer to Finisher Service Manual.

Paper remains on the sensor (finisher buffer path). At this time, the sen sor (diverter gate) is tur ned off . Refer to Finisher Service Manual.

Sensor (lower media exit) i s not turned off within the specifie d ti m e after the finisher sensor (lower media exit) is turn ed on.

At this time, the sen sor (bridge unit media exit) i s turned off.

Refer to Finisher Service Manual. Sensor (buffe r pat h) i s not turned on within the

specified time after the sensor (finisher media entrance) is turned on.

At this time the sensor (br idge unit media exit) is turned on.

Refer to Finisher Service Manual.

Diagnostic information 2-9

4024-110

Error code o r

message

284.02 Paper jam Check areas

G2, G3

284.03 Paper jam Check area

284.04 Paper jam Check area H

284.05 Paper jam Check area H

285.00 Paper jam Check area H

Error con tents Description/Action

Sensor (lower media exit ) on jam B

Sensor (lower media exit ) on jam C

Sensor (lower media exit ) off jam B

Sensor (lower media exit ) Static jam

Finisher set eject jam Finisher sensor (compiler media in) is not turned on

Sensor (buffe r pat h) i s not turned on within the specifie d ti me after the sensor (bridge unit media entrance) is turned on.

At this time, the sen sor (finisher media entr ance) is turned on.

Refer to Finisher Service Manual. Finisher sensor (lower media exit) not t urned on

within the specif ied time after the sensor (b uffer path) is turned on.

Refer to Finisher Servi ce Manual.

Finisher sensor (lower media exit) not t urned off within the specif ied time after the finisher sensor (lower media exit) on.

At this time, the sen sor (finisher media entr ance) is turned on.

Refer to Finisher Service Manual. Paper remains on the sensor (lower media exi t).

Refer to Finisher Service Manual.

within the specified time after the media eject mot or is turned on.

Refer to Finisher Service Manual.

286.00 Paper jam Check area H

287.00 Check area F

287.01 Check area F

287.02 Paper jam Check areas

G1, G3

Sensor (compiler med ia i n) Static jam

Sensor (upper media ex it) on jam A

Sensor (upper media ex it) off jam A

Sensor (upper media ex it) on jam B

Paper remains on the sensor (compiler medi a in). Refer to Finisher Servi ce Manual.

Sensor (upper media exi t) i s not turned on wit hin t he specified time after the sensor (finisher media entrance) is turned on.

At this time, the sen sor (bridge unit media exit) i s turned on.

Refer to Finisher Service Manual. Sensor (upper media exi t) i s not turned off wi thi n the

specifie d ti me after the sensor (upper medi a exit) is turned on.

At this time, the sen sor (bridge unit media exit) i s turned on.

Refer to Finisher Service Manual. Sensor (upper media exi t) i s not turned on wit hin t he

specified time after the sensor (finisher media entrance) is turned on.

At this time, the sen sor (bridge unit media exi t) is on state

Refer to Finisher Service Manual.

2-10 Printer Se rvice Manual

+ 335 hidden pages