Lexmark X125, 4412-001 Service Manual

Lexmark X125

• Table of Contents

• Start Diagnostics

• Safety and Notices

All-In-One

4412-001

• Trademarks

•Index

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

4412-001

Edition: July 2002
The following paragraph does not apply to any country where such provisions are

inconsiste nt with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS

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

This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.

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

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

Other trademarks are the property of their respective owners.

© Copyright Lexmark International, Inc. 2002.
All rights reserved.

UNITED STA TES 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
DF ARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.

P/N 12G9148

4412-001

Table of Contents

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x

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

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

Printer Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

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

Power and Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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

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

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

Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . 2-1

POST Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Symptom Ta bles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Carrier Transport Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-7

CIS Assembly Service Check. . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Scanner Motor with Gear Assembly Service Check . . . . . . . 2-10

Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . 2-11

Paper Feed Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Paper Path Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Scan/Copy Quality Service Check . . . . . . . . . . . . . . . . . . . . 2-18

Fax/Telephone Communication Service Check . . . . . . . . . . 2-19

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

Theory of Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Scanner Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Drive Feed Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Contact Image Sensor (CIS). . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Document Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

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

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

Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

iii

4412-001

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

Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

General Precautions on Removals. . . . . . . . . . . . . . . . . . . . . .4-3

CIS White Roller Assembly Removal. . . . . . . . . . . . . . . . . . . .4-4

Top Cover Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . .4-5

Rollers (Drive Feed Roller Assembly, Exit Shaft) Removal . . .4-6

CIS (Contact Image Sensor) Removal. . . . . . . . . . . . . . . . . . .4-7

Scanner Motor with Gear Assembly Removal . . . . . . . . . . . . .4-9

Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Line Interface Board Removal . . . . . . . . . . . . . . . . . . . . . . . .4-12

Operator Panel Assembly Removal . . . . . . . . . . . . . . . . . . . .4-13

Printer Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

ASF Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Maintenance Station Removal . . . . . . . . . . . . . . . . . . . . . . . .4-17

Carrier Assembly with Belt Removal . . . . . . . . . . . . . . . . . . .4-18

System Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Mid Frame Assembly with Exit Rollers Removal . . . . . . . . . .4-20

Large Feed Roller Assembly with Gear Removal . . . . . . . . .4-21

Paper Feed Motor Assembly with Gears Removal . . . . . . . .4-22

Carrier Transport Motor Removal. . . . . . . . . . . . . . . . . . . . . .4-23

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

System Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Line Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

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

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

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

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

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

iv Service Manual

4412-001

Safety Information

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

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

• The maintenance information for this product has been

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

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessar y pr ec autions.

Consignes de Sécurité

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

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

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance
qualifié.

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

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

Safety Information v

4412-001

Norme di sicurezza

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

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

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il

rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.

Sicherheitshinweise

• Dieses Produkt und die zugehörigen Komponenten wurden

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

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

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

vi Service Manual

4412-001

Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para

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

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

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

Informações de Segurança

• Este produto foi concebido, testado e aprovado para satisfazer

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

• As informações de segurança relativas a este produto

destinam-se a profissio nai s 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.

Safety Information vii

4412-001

Informació de Seguretat

• Aquest producte està dissenyat, comprovat i aprovat per tal

d'acomplir les estrictes normes de seguretat globals amb la
utililització de components específics de Lexmark. Les
característiques de seguretat d'algunes peces pot ser que no
sempre siguin òbvies. Lexmark no es responsabilitza de l'us
d'altres peces de recanvi.

• 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 serv e i d’aquest producte.
El personal professional ha d’estar-ne assabentat i prendre les
mesures convenients.

viii Service Manual

4412-001

Safety Information ix

4412-001

Preface

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

1. General Information contains a general description of the All­In-One and the maintenance approach used to repair it. Special
tools and test equipment are listed.

2. Diagnostic Information contains an error indicator table,
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 symptoms of All-In-One problems.

4. Repair Information provides instructions for making All-In-One
adjustments and removing and installing FRUs.

5. Connector Locations uses illustrations to identify the
connector locations and test points on the All-In-One.

6. Preventive Maintenance contains the lubrication specifications
and recommendations to prevent problems.

7. Parts Catalog contains illustrations and part numbers for
individual FRUs.

x Service Manual

4412-001

1. General Information

The Lexmark™ X125 All-In-One is a letter quality print, fax, copy,
and scan machine. The printhead uses small heater plates and
nozzles to control ink flow and the formation of characters on the
print media. The printhead assembly and ink supply are combined
into a single unit. Print cartridges are available as a customer
replaceable supply item. Dual printheads provide color and true
black printing without changing printheads. The number and size of
inkjets or nozzles, in the printhead, determines the overall quality
and capability of the printer. The black cartridge has a total of 208
nozzles and installs on the right. The color cartridge has a total of
192 nozzles and installs on the left. The printer is capable of printing
in both directions from either cartridge.

General Information 1-1

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Specifications

Printer Engine

Technology Thermal Inkjet

2-pin and printhead swapping
type

Speed Color 8 ppm at Draft Mode

Mono 16 ppm at Draft Mode

Resolution Color 600 X 600 dpi (1200 X 2400

dpi addressable)

Mono 600 X 600 dpi (1200 X 2400

Printing Width 203 mm
Feeding Method Automatic 100 sheets of 20 lb cut s heets

Manual Tray No
Emulation Host Based Printing (GDI)
Printer Driver Windows 98/ME, Windo ws

Interface USB Interface

dpi addressable)

(Max 10 mm)

2000/Windows XP

Printhead

Babbage Mono Standard Birch Color

Printhead 208 nozzles 192 nozzles
Ink Type Pigment Dye
Ink Color Black Color
Ink Yield About 600 sheets About 200 sheets

1-2 Service Manual

4412-001

Facsimile

General Compatibility ITU-G3

Scan Method CIS
Scan Width Maximum 216 mm, Effective 210 mm
Scan Resolution 600 X 1200 dpi
Scan Speed 6 seconds
Feeding Method Sheet Feed
ADF 30 sheets of 20 lb
Guide Document Input Guide
Stacker Document Output Stacker/Paper

Paper Tray Bin Type (without Manual Tray)
Modem Speed 33.6 Kbps
Coding Method MH, MR, MMR, Error Correction Mode
LCD 2 lines of 16 characters each

Scanning Resolution and

Type

Contrast Darkest/Darken/Normal

Memory Capacity 1 Mbyte

Back-up Time 15 sec (Continuous power failure,

Confidential No
Forced Memor y TX Yes

Stacker

Standard: 200 X 100 dpi
Fine: 200 X 200 dpi (default)
Super Fine: 300 X 300 dpi
Color: 200 X 200 dpi

(Standard: Low quality, Fine: High
quality compression)

Lighten/Lightest

typically 1-2 minutes )

Memory RX Automatic reception when paper empty.

General Information 1-3

4412-001

Telephone Speed Dial 70 locations

Chain Dial No
On-Hook Dial Yes, 1-Key
Last Number Redial Yes, 1-Key
Auto Redial Yes
Hold and Mute No
Pause Yes, u se Redial Key
Ringer Volume S/W Option Setting (4 steps)
Tone/Pulse Select S/W Option Setting
DRPD USA: Yes, Other Countries: Yes

Report and
List

Copy Multipage Copy Up to 99 pages

Telephone
I/F

Others Sensors Paper Jam

TX/RX Journal Yes
Image TCR Yes, reduction of first page sent by

System Data Yes
Telephone Number

List
Self Test Yes

Grayscale 256 levels
Reduction and

Enlargement

Answering I/F Yes
Extension Phone 1-jack, extension phone transfer

Real-Time Clock No
RTI Yes

Memory TX

Yes

25% - 200%
(Reference is the top center of
document.)

1-4 Service Manual

4412-001

Scanner

Compatibility TWAIN
Technology Platen CIS
Light Source for Color CIS RGB LEDs (Line Order Control)

Power and Size

Power Source 110V-240V / 50Hz-60Hz
Dimensions 440.6 X 319.6 X 205.4 mm
Weight (Packed) 15.3 lbs (Packed Weight)

Abbreviations

ASF Auto Sheet Feed
B/M Bill of Material
CIS Contact Image Sensor
EOF End of Form
ESD Electrostatic Discharge
FPC Flat Printhead Cable
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LCD Liquid Crystal Display
LVPS Low Voltage Power Supply
OEM Original Equipment Manufacturer
V ac Volts alternating current
V dc Volts direct current
ZIF Zero Insertion Force

General Information 1-5

4412-001

1-6 Service Manual

4412-001

2. Diagnostic Information

Start

Power-On Self Test (POST) Sequence

1. Power Up Please Wa it is displayed on the LCD.

2. Carrier moves to the left and the paper feed motor runs then
stops.

3. Carrier returns to the right.

4. Ready, ANS/FAX, and the Date and Time display when POST is
complete.

If your printer completes POST with no errors, go to the “Symptom

Tables” on page 2-3. Locate the symptom and take the indicated

action.
If your printer does not complete POST, locate the symptom in the

following table and take the indicated action.

Diagnostic Information 2-1

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POST Symptom Table

Symptom Action

LCD or operator
panel button s do
not work and no
motors run

Paper f ee d
gears do not
turn

Carrier does not
move

Carrier slams
side frame

CIS light does
not turn on

Go to the “Power Service Check” on page 2-15. If okay,
go to the “Operator Pane l Problems” on page 2-3.

Go to the “Pa per Feed Service C heck” on page 2-12.

Go to the “Carrier Transport Service Check” on

page 2-7.

Go to the “Carrier Transport Service Check” on

page 2-7.

Go to the “CIS Assemb l y Service Ch eck” on page 2-9.

2-2 Service Manual

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Symptom Tables

Locate the symptom in the following tables and take the appropriate
action.

Carrier Transport Problems

Symptom Action

• No carrier movement

• Slow carrier movement

• Carrier stops

• Carrier slams side frame

Go to the “Carrier Tr ansport

Service Check” on page 2-7.

Maintenance Station Problems

Symptom Action

Maintenance station:

• Fails to cap the printheads

• Fails to clean the printheads

Go to the “Maintenance Station

Service Check” on page 2-11.

Operator Panel Problems

Symptom Action

• Buttons do not work

• LCD does not display

Check operator panel cable
connection at P9 on the system
board. Run the “Power-On Self

Test (POST) Sequence” on
page 2-1. If the LCD or buttons fail,

check connection P9. If the problem
remains, replace the operator panel
assembly. Go to the “Operator

Panel Assembly Removal” on
page 4-13.

If the problem sti ll e xists , rep lace the
system board. Go to the “System

Board Removal” on page 4-19.

Diagnostic Information 2-3

4412-001

Symptom Action

Document scan sensor does not
detect document

Check operator panel cable
connector P9 on the sy stem board. If
okay, go to the “Scanner Motor

with Gear Assembly Service
Check” on page 2-10. If the

scanner motor is working correctly,
replace the oper ator panel ass embly.
Go to the “Operator Panel

Assembly Removal” on pa ge 4-13.

2-4 Service Manual

4412-001

Printer Communication Proble m

Symptom Action

Not able to print Self Test Page Check the USB cable and system

board cable connections. If okay,
replace system board. Go to the

“System Board Removal” on
page 4-19.

Scanner Problems

Symptom Action

Light does not turn on Go to the “CIS Assembly Service

• Scanned images are faded, or
colors are dull, blurry or fuzzy.
Images are slanted or crooked
and the straight lines in the
image appear to be jagged or
uneven.

• Blank co pies

• Scanner motor does not run

• Document sensor does not

work

Check” on page 2-9 .

Go to the “Scan/Copy Quality

Service Check” on page 2-18.

Go to the “Scanner Motor with

Gear Assembly Service Check”
on page 2-10.

Go to the “Operator Panel

Problems” on page 2-3.

• CIS white roller assembly slips

• Paper does not feed correctly

Go to the “Paper Path Service

Check” on page 2-14.

Diagnostic Information 2-5

4412-001

Paper Feed Problems

Symptom Action

• Fails to pick paper

• Picks more than one sheet of

paper

• Picks paper but fails to feed

• Paper jams

• Paper fails to exit

• Noisy paper feed

Envelopes fail to feed Go to the “Paper Feed Service

Paper skews Go to the “Paper Path Service

Go to the “Paper Feed Service

Check” on page 2-12.

Check” on page 2-12.

Check” on page 2-14.

Power Problems

Symptom Action

No power in machine, motors do
not operate

Go to the “Power Service Check”

on page 2-15.

Print Quality Problems

Symptom Action

• Voids in characters

• Light print

• Prints off the page

• Fuzzy print

• Carrier moves but no print

• Printhead dries prematurely

• Colors print incorrectly

• Vertical alignment off

Go to the “Print Quality Service

Check” on page 2-16.

• Ink smearing

• Vertical streaks on paper

• Print lines crowded

2-6 Service Manual

Go to the “Paper Feed Service

Check” on page 2-12.

4412-001

Service Checks

Carrier Transport Service Check

FRU Action

1 System Board

Carrier Transport
Motor

2 Carrier Transport

Motor

Check the carrier transport motor connector P4. If
connected, check for approximately 29 volts on
pins 1 and 2 or at the wire connections located on
the rear of the carrier transport motor. If voltage is
incorrect, replace the system board. If voltage is
correct, check the motor for shorts.

Check the motor for binds, or loose motor pulley.
A noisy or chattering motor, or a motor that fails to

turn, can be caused by:

• An open or short in the motor

• An open or short in the motor driver

on the system board

• A bind in the carrier transport

mechanism

With the carrier transport motor cable (P4)
disconnected from the syst em board, che ck for 0
to 16 ohms between the following pins on the
motor:

P4-1 and P4-2

If the readings are incorrect, replace the print
engine. Go to the “Carrier Transport Motor

Removal” on page 4-23.

3 Carrier Guide Rod Clean the carrier rod.

Note: Lubricate the rod and th e carrier rod bea ring
surfaces with grease P/N 99A0394.

Diagnostic Information 2-7

4412-001

FRU Action

4 Encoder Strip

Carrier Assembly
with Belt

5 Carrier Transport

Belt
Idler Pulley
Assembly

6 Maintenance

Station

7 Access Door

Sensor

Check the encoder strip for proper installation.
Also, chec k it for wear, dirt, and grease . R ep lac e i f
needed.

Be sure all printhead connectors are fully sea ted.
Check the cables for damage.

If the encoder strip and all connections are okay,
but the carrier still slams the side frame, replace
the carrier assembly with belt. Go to the “Carrier

Assembly with Belt Removal” on page 4-18. If

problem remains , replac e the syst em board. G o to
the “System Board Removal” on page 4-19.

Check for worn, loose or broken parts. Check for
obstructions blocking carrier movement. If pulley
assembly is damaged, replace.

Lubricate carrier to carrier frame enga geme nt with
grease P/N 99A0394.

A problem with the maintenan ce sta tion can ca use
carrier movemen t prob lems at the right margi n. Go
to the “Maintenance Station Removal” on

page 4-17.

If the carrier does not move toward the cartridge
load position when the access door is opened,
verify that power is on. If the carrier still doe s not
move, check connector P11 pin 1 for
approximately 3 volts, with the door open. If the
voltage is correct, replace the sensor. Disconnect
P11 from the system board before removing
sensor. If the voltage is incorrect, replace the
system board. Go to the “System Board

Removal” on page 4-19.

2-8 Service Manual

4412-001

CIS Assembly Service Check

The CIS lamp does not light when scanning is in process.

FRU Action

1 CIS Assembly If light does not come on during the

scanning process, check connector
P2 on the system board. If the
connection is okay, check for a
voltage reading of approximately 4
volts from ground to P2-2 pin. If
voltage is correct, replace the CIS
assembly. Go to the “CIS (Contact

Image Sensor) Removal” on
page 4-7. If voltage is incorrect,

replace the system board. Go to the

“System Board Removal” on
page 4-19.

Diagnostic Information 2-9

4412-001

Scanner Motor with Gear Assembly Service Check

Motor will not run.

FRU Action

1 Scanner Motor with Gear

Assembly

Check scanner motor for shorts.
Disconnect connector P6 from the
system board and check for
approximately 6 ohms between the
following pins on the motor
connector.

P6-1 and P6-2

If the ohms reading is incorrect,
replace the scanner motor as sembly.
If the motor does not come on during
the scanning process, check
connector P6 on the sy stem board. If
the connection is okay, check for
voltage reading of approximately 29
volts at pins

P6-1
P6-2
P6-3
P6-4

If voltage is correct, replace the
scanner motor with gear assembly.
Go to the “Scanner Motor with

Gear Assembly Removal” on
page 4-9. If voltage is incorrect,

replace the system board. Go to the

“System Board Removal” on
page 4-19.

2 Document Scanner Sensor To check the document scanner

sensor, insert a sheet of paper or
press the sensor to see if the
scanner motor is working. Go to

“Operator Panel Problems” on
page 2-3.

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4412-001

Maintenance Station Service Check

The maintenance station has three functions:

1. Wipes the printhead nozzles to clean them of dirt.

2. Provides a place for printheads to fire all nozzles, keeping them
clear prior to printing.

3. Seals the printhead when it is not being used to prevent the
nozzles from drying.

FRU Action

1 Maintenance

Station Assembly

As the carrier moves to the right over the
maintenance station, a slot on the bottom of the
carrier engages a tab on the sled of the
maintenance station causing the cap to rise and
seal the printhead. Carrier movement to the left
uncaps the printhead. The wiper cleans the
printhead nozzles as the carrier lea ves the
maintenance statio n. The wiper cleans the
printhead only when the carrier is moving to the
left. Do not wipe the printhead nozzles when the
carrier is moving to the right. After the cleaning
operation is complete, a tab on the maintenance
station engages a tab on the carrier, causing the
wiper to lower.

Check the maintenance station for worn or broken
parts. Replace if nee ded. Go to t he “Maintenance

Station Removal” on page 4-17.

Worn wipers cau se degr aded print qual ity just af ter
a maintenance cleaning. Check for loose or worn
wipers.

Worn caps caus e the p rinthead no zzles to dry and
clog. Check for loose or worn caps.

Diagnostic Information 2-11

4412-001

Paper Feed Service Check

If your machine does not have paper jam problems, continue with
the service check. If your machine does have a paper jam, examine
it for the following before you begin the service check:

• Check the entire paper path for obstructions.

• Be sure there is not too much paper in the sheet feeder.

• Be sure the correct type of paper is being used.

• Check for static in the paper.

FRU Action

1 System Board Run the “Power -On Self Test (POST) Sequence”

on page 2-1. Replace parts as needed. To check

the paper feed motor, disconnect the paper feed
connector P5 and check for approximately 4 ohms
between pins 1 and 4. If the reading is incorrect,
replace the paper fee d motor assemb ly with gears .
Go to the “Paper Feed Motor Assembly with

Gears Removal” on page 4-22. If the reading is

correct, replace the system board. Go to the

“System Board Removal” on page 4-19.

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4412-001

FRU Action

2 Paper Feed Motor A noisy or chattering motor or a motor that fails to

3 Auto Sheet

Feeder Assembly

turn, can be caused by:

• An open or short in the motor

• An open or short in the motor driver on the

system board

• A bind in the paper feed mechanism
With the paper feed motor cable P5 disconnected
from the system board, check for approximately 4
ohms between the fo llowing pins on the motor:

Pin 1 to Pin 4
If the readings are incorrect, replace the pape r

feed motor a ssemb ly w ith ge ars . Go to t he “Paper

Feed Motor Assem b ly with Gear s Removal” on
page 4-22.

Although the paper feeds in a forward direction
only, the paper feed motor turns in two directions.
If the paper feed motor turns in one direction only,
replace the system board. Go to the “System

Board Removal” on page 4-19.

Binds in the paper feed motor or gear train can
cause intermittent f als e p ape r jam erro rs . R emove
the paper fee d motor and chec k the shaft f or binds .
Also check for a loose or worn motor gear.

Check the pick roller for wear.

4 Mid Fram e

Assembly

5End-of-Forms

Flag and Spring

Check the following for wear:

• Small F e ed roll ers

• Large Feed roller

• Exit roller

• Star rollers

If the mid frame assembly needs to be replaced,
go to the “Mid Frame Assembly with Exit

Rollers Removal” on page 4-20.

Check for binds or damage.

Diagnostic Information 2-13

4412-001

Paper Path Service Check

Examine the machine for the following before you begin this service
check:

• Check the entire paper path for obstructions.

• Be sure the correct type of paper is being used.

• Be sure the printer is installed on a flat surface.

FRU Action

1 Large and Small

Feed Rollers

2 Small Feed Ro ller

Springs

3 Auto Sheet

Feeder Assembly

4 Mid Frame Asm Check the following for wear:

5End-of-Forms

Flag

6 White Roller

Assembly

Check for wear and binds.

Check for damage or disconnected springs.

Check the pick roller for wear.

• Exit roller

• Star rollers

Check for binds or damage.

Check for correct installation. Check gear and
bushings for dama ge. If damaged, replace. Go to
the “CIS White Roller Assembly Removal” on

page 4-4.

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4412-001

Power Service Check

FRU Action

1 Power Supply Plug the machine into an outlet. Check for

2 Printhead Cables

Paper Feed Motor
Carrier Transport
Motor
Operator Panel

3 System Board If the symptom has not changed, replace the

approximately 30 V dc at P1 pin 3. Check
connector (CON1 ) at the po wer supply. If voltage is
incorrect, replace the power supply.

Unplug the printer. Disconnect the printhead
cables and plug in the printer. Look for a symptom
change. Chec k the f ai li ng part for sh orts and
replace as necessary.

Repeat this procedure for the carrier transport
motor, paper feed motor, and operator panel.

system board. Go to the “System Board

Removal” on page 4-19.

Diagnostic Information 2-15

4412-001

Print Quality Service Check

FRU / Function Action

1 Printhead

Cartridge

2 Color Printhead

Cartridge Cross
Contamination

3 Carrier Assembly Reseat the printhead cables in the system board

4 System Board

Carrier
Assembly

Be sure the machine contains good print
cartridges.

Cross contamination of color inks results in
incorrect colors printed, as when green prints for
yellow, (when yellow and blue are mixed in the
printhead cartridge). This proble m resolv es quick ly
as the printhead cartridge is used.

If cross contamination occurs, check the following:

• The maintenance station wiper for damage.

• The printhead nozzle plate was resealed with

tape.

and check the following parts for wear or damage:

• Printhead Cartridge Latch

• Latch Spring

• Carrier

Print the self test page. To enter the self test page ,
press Setup and then Menu button until “Print
Report” is displayed. Press Options button until
“Self Test” is displayed. T hen pre ss th e t o p rint the
self test page. Lo ok f or a brea k in the diagon al lin e
of the nozzle test pattern. A broken line indicates
one or more print noz zles are not workin g. Run the
test again to verify the failure.

5 Maintenance

Station

2-16 Service Manual

Check the gold-plated contacts on the end of the
printhead carrier cable for dirt, wear, a nd damage.
Use only a clean dry cloth to clean the contacts. If
a problem is found with contacts on the carrier,
replace the carrier. Go to the “Carrier Assembly

with Belt Removal” on page 4-18.

If the symptom remains , replace the system board .
Go to the “System Board Removal” on

page 4-19.

Intermittent nozzle f ailure s can be caus ed b y worn
parts in the maintenance station. Go to the

“Maintenance Station Remov a l” on pa ge 4-17,

and then return to this check.

4412-001

FRU / Function Action

6 Paper Feed Ink smudging and smearing can be caused by

7 Carrier T ransport Blurred print and voids c an be caused by problems

8 Alignment Uneven vertical lines can be adjusted by

paper problems or problems in the paper feed
area.

Check the following:

• Correct type of paper is being used. Also check

the paper for curl or wrinkles.

• Feed rollers for wear, dirt, or looseness.

• Gears for wear or binds.

• P aper path for obstructions.

in the carrier transport area. Check the following:

• Carrier transport belt for wear.

• Carrier guide rod for wear or dirt. If dirty, clean

and lubricate.

• Carrier to carrier frame engagement should be

lubricated with grea se P/N 99A0394.

• Idler pulley parts for wear, damage, or

looseness.

performing the printhead ali gnmen t adju st ments i n
the maintenance mode. The user is directed,
through the “Setting up System in User Mode”

on page 3-3, to perform the printhead alignment

adjustments , whe n replac ing a p rinthea d cartridge.

Diagnostic Information 2-17

4412-001

Scan/Copy Quality Service Check

FRU / Function Action

1 Scanned images

are faded, or
colors are dull,
blurry, or fuzzy.
Images are
slanted or
crooked and the
straight lines in
the image appear
to be jagged or
uneven.

2 Blank copies If there are blank copie s f ound, make s ure that the

3 Scanning error Ensure the USB cable is correctly installed.

Check the lighter/darker settings to see if it is
correct.

• From the operator panel

• From the Scan & Copy Control Program

Check to see if there is any dust or debris on the
glass lens of the CIS. This may cause a poor
image.

origin al document is facing down.
Check the print cartridges to see if they ne ed to be

cleaned or replaced.

Ensure the USB cable is proper for USB
specification, version 1.1.

Start the system after twain driver is reinstalled.
If error still occurs, replace the system board. Go

to the “System Boar d Rem o val” on page 4-19.

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4412-001

Fax/Telephone Communication Service Check

FRU / Function Action

1 Line Int erface

Board or System
Board

Cannot make
telephone
connection to
other fax.

2 Cannot receive

faxes

No dial tone
Verify correct dialing method (tone or pulse). Are

TEL and LINE connectio ns rev ersed? V erify phone
number and availability of other fax machine.

Before dialing, press Speaker so you can hear the
dialing process . You should hear the ring a nd a 0.5
second 1000 Hz calling tone from your machine, a
1 second pause, then the 3 second 2100 Hz fax
response tone and a 1650 Hz - 18 50 Hz “warbling”
handshaking tone from the called machine.

Check the connectors on the line interface board
P1 and P2. If okay, check connector CN15 located
on the system board. If prob lem stil l e xists, re place
the line interf ac e boa rd. G o to the “Line Interface

Board Removal” on page 4-12. If this does not

correct the prob lem, re place the s ystem boar d. Go
to the “System Board Removal” on page 4-19.

Are TEL and LINE connections reversed? Is a
telephone on the same line off the hook? Is the
machine connected to the wrong telephone line?

Check for a damaged line cord to the machine.
Check telephone and line cord connections.

Diagnostic Information 2-19

4412-001

2-20 Service Manual

4412-001

3. Diagnostic Aids

Theory of Mechanism

Scanner Mechanism

The scanner mechanism consists of components which feed, scan,
and eject the documents that are to be copied or transmitted to a
remote facsimile unit. These components and their functions are
explained below.

Drive Feed Roller Assembly

The drive feed roller assembly, consisting of various rollers, rubber
pad, and springs, automatically separates and feeds the pages of a
document over the scanning area and stacks them on the document
exit tray.

Documents up to 15 pages can be placed in the drive feed roller
assembly for scanning. The leading edge of the document moves
the document detect sensor lever when the operator slides the stack
into the drive feed roller assembly. The scan motor starts to rotate
when the document detect sensor detects the leading edge of the
document. The roller feeds the first page of the document into the
feeder.

The scan motor stops when the leading edge of the page actuates
the document scan sensor. The page is now in the scan position.

The drive feed roller assembly rubber pad prevents multiple sheets
from being fed. A spring provides force that the pad places on the
document pages for proper separation.

The scan motor is turned on when the machine is ready to scan the
document and drives the feed roller at a speed determined by the
resolution selected. The scan motor stops after a set period of time
when the trailing edge of the page releases the document scan
sensor. If another page is detected as the trailing edge of the page
releases the document scan sensor, the next page feeds to the scan
position. The exit roller pushes the page out onto the document exit
tray where it is stacked.

Diagnostic Aids 3-1

4412-001

Contact Image Sensor (CIS)

The contact image sensor unit consist of LEDs, rod lens array , and a
photo sensor. The LEDs illuminate the document to be scanned
when the leading edge is detected by the document scan sensor.
The LEDs turn off when the document exits the scanner mechanism.

The LEDs illuminate the document to obtain an image from the
document through the rod lens array, where the image is translated
into voltage levels.

Document Sensors

There are two document sensors in the scanner mechanism; the
document detect and the document scan sensor. The document
detect sensor, detects whether or not a document is loaded, and the
document scan sensor detects the scan position of the document.
The scanner mechanism consists of components which feed, scan,
and eject the documents that are to be copied or transmitted to a
remote facsimile unit.

Service Mode

In service mode (tech) mode, the technician checks the machine
and performs various tests to isolate the cause of a malfunction.

To enter the service mode, press Menu, #, 1, 9, 3, 4 in sequence,
and the LCD briefly displays T. The machine has entered service
(tech) mode. While in service mode, the machine still performs all
normal operations. T o return to normal user mode, press Menu, #, 1,
9, 3, 4 in sequence again, or turn the power off and then on by
unplugging and plugging the power cord.

Options changed while in service mode do not remain changed
unless you clear the machine memory.

3-2 Service Manual

4412-001

Setting up System in User Mode

Setup Item Default

Date Jan/01/01
Time 12:00:00P

Print Report Fax Confirm

Maintenance Cartridge Clean

Paper Size Letter/A4/Legal Letter
Ringer Volume Off/Low/Medium/High Medium
Fax Print Letter Quality/

Fax Forwarding Off/Forward/ Fo rward

Fax Receive Mode FAX/TEL/ANS/FAX/

Setup DRPD Learn
Auto Journal Yes / No

Month - Day - Year
Hour - Minute - AM/PM

Transmit Log
Receive Log
Speed Send List
Self Test

Cartridge Align
Scanner Init

Draft Quality

and Print

DRPD

Jan/01/01
12:00 PM

Letter Quality

Off

ANS/FAX

Dial Mode Pulse / Tone
Default Setting Fax Type

Copy Size
Copy Collate
Copy Contrast
Copy Type
Copy P ape r Type

Diagnostic Aids 3-3

4412-001

Setting up System in Service Mode

Setup Item Default

CIS Test Red, Green, and Blue

Aging Test Scanner Aging/

Print Report Fax Confirm

Maintenance Cartridge Clean

Program Download
Message Confirm On/Off/Error On-Error
Remote RCV Code (0-9) 9
EMC Mode Yes/No Yes

maximum and minimum
peak levels

Printer Aging

Transmit Log
Receive Log
Speed Send List
Self Test
Protocol Dump
ASF Test
System Data
NVRAM Dump
CIS Pattern

Cartridge Align
Scanner INIT

Auto Reduction On/Off Vertical Only On
Retry Interval (1-7) 3
Retry Count (0-2) 2
Answer on Rings (1-7) 1
Print RTI Yes / No
Modem Test FSK/2400/4800/7200/

9600/12000/14400 bps/
21600 bps/26400 bps/
28800 bps/31200 bps/
33600 bps/1100/1650/
1850/2100 Hz

3-4 Service Manual

4412-001

Setup Item Default

DTMF Test
ROM Test
Modem Speed Item

(1-6)

Set TX Level (1-15) 12
Set RX Level (40-50) 43
Pau se Time (1-9) 3

FSK/2400/4800/7200/
9600/112000/14400/
33600/12000/9600/
7200/4800/2400

33600 bps

CIS Test

The test adjusts the light of CIS. It is already set at CIS Test to get
optimum quality.

Warning: Shading profile must be made after downloading a new
firmware. If not, the system will not work properly.

1. Load all white document in scanner unit.

2. Press Setup and ‘CIS Test Press Start’ is displayed.

3. Press Start and ‘Shading...’ is displayed.

4. After scanning, shading waveform is printed.

5. After shading waveform has printed, press Stop.

6. Tu rn off system and turn on.

Aging Test

Scanner Aging - Scanner part aging
Printer Aging - Printer part aging.

Print Report

1. Press Setup.

2. Press Menu until ‘Print Report’ is displayed.

3. Press Options to select the log you want to print.

4. Press Start or Setup to print the report.

Diagnostic Aids 3-5

4412-001

Maintenance

1. Press Setup.

2. Press Menu until ‘Maintenance’ displays.

3. Press Options to select, cartridge clean, cartridge align and
scanner init.

4. Press Start after you select.

Progr am Download

1. Press Setup.

2. Press Menu four times until ‘Program Download Press Start’ is
displayed.

3. Press Start.

4. Download your new firmware files from PC.

Note: Be sure the USB cable is connected to the PC when you are
running this test. If cable is not connected, it may cause a fatal error.

Message Confirm

A message confirmation report shows whether the transmission was
successful or not and how many pages were sent.

1. Press Setup.

2. Press Menu five times until ‘Message Confirm, Report, On
Report, Off Report, Error’ is displayed.

3. Press Options to print a confirmation report automatically each
time you send a fax (On). Press Options to turn this feature off.
Press Options to print only when an error occurs and the
transmission was not succ essful. Press Start or Setup to set
the time you want to select.

Auto Journal

A journal shows specific information concerning transmission or
reception activities, the time and dates of up to 40 of the most recent
transmissions or receptions.

1. Press Setup.

2. Press Menu until ‘Auto Journal’ displays in the top line of the
LCD.

3-6 Service Manual

4412-001

3. Press Options to print the journal automatically after every 40
transmissions or receptions (Yes). Press Options to print
journal manually (No).

Remote RCV Code

The remote receive code lets you initiate fax received from an
extension phone plugged into the EXT jack. If you pick up the
extension phone and hear fax tones, enter the remote receive code
and the fax starts receiving. The password is preset to 9.

1. Press Setup.

2. Press Menu until ‘Remote RCV Code’ displays on the top line.

3. Enter the code you want, 0 to 9 on the number keypad.

Dial Mode

Select the type of dial system your fax machine is connected to.

1. Press Setup.

2. Press Menu until ‘Dial Mode’ displays in the top line of the LCD.

3. Press Start or setup when Tone Message is displayed if the fax
machine is connected to a tone (Touch Tone) dial line.

4. Press Start or Setup when Pulse Message is displayed if the
fax machine is connected to a pulse (Rotary) dial line.

ECM (Error Correction Mode)

This mode compensates for poor line quality and ensures accurate,
error-free transmission with another ECM-equipped facsimile
machine. If the line quality is poor, transmission time may be
increased when ECM is enabled.

1. Press Setup.

2. Press Menu until ‘ECM Mode’ displays.

3. Press Start or Setup when Yes is displayed to turn on the Error
Correction Mode. Press Start or Setup when No is displayed to
turn off the Error Correction Mode.

Diagnostic Aids 3-7

4412-001

Auto Reduction

When receiving a document as long or longer than the paper
installed in your machine, the machine can reduce the data in the
document to fit into your recording paper size.

Turn on this feature if you want to reduce an incoming page that may
otherwise need to be divided into two pages with only a small portion
on the second page. If the fax machine cannot reduce the data to fit
one page with the feature enabled, the data is divided and printed in
actual size on two or more sheets.

1. Press Setup.

2. Press Menu until ‘Auto Reduction’ displays. To turn only the
vertical reduction feature On, press Start or Setup when On is
displayed. The machine reduces an incoming page containing
overflow data only in vertical. Press Start or Setup when Off is
displayed to turn this feature on.

Discard Size

When receiving a document as long as, or longer than, the paper
installed in your fax machine, you can set the fax machine to discard
any excess image at the bottom of the page to fit into the recording
paper size. If the receiving page is outside the margin you set, it
prints on two sheets of paper at the actual size. If the data is within
the margin, and the Auto Reduction feature is turned on, it reduces
to fit into the appropriate size paper (Discard does not take place). If
the Auto Reduction feature is turned Off or fails, the data within the
margin is discarded.

1. Press Setup.

2. Press Menu until ‘Discard Size’ displays in the top line of the
LCD.

3. Enter the length using the numbers on the keypad.

Retry Interval

1. Press Setup.

2. Press Menu until ‘Retry Interval’ displays.

3. Enter the number of minutes (from 1 to 7) using the numbers on
the keypad.

3-8 Service Manual

4412-001

Retry Count

1. Press Setup.

2. Press Menu until ‘Retry Count’ displays.

3. Enter the number of attempts (from 1 to 2) to redial the number.
If you enter 0, the machine does not redial.

Answer On Rings

You can select the number of times your machine rings before
answering an incoming call. If you are using your machine as both a
telephone and a fax machine, we suggest you set the ring count to at
least 4 to give you time to answer.

1. Press Setup.

2. Press Menu until ‘Answer On Rings’ displays.

3. Enter a number from 1 through 7 on the keypad.

Print RTI (Receive Terminal ID)

This feature lets the machine automatically print the receive terminal
ID (if registered), page number, and the date and time of the
reception at the bottom of each page on the received document.

1. Press Setup.

2. Press Menu until ‘Print RTI’ displays.

3. Press Start for yes to print RTI, or press Cancel for no.

Diagnostic Aids 3-9

4412-001

Modem Test

The modem sends various transmit signals on the telephone line.
You can check the following:

– FSK
– Tones: 1100Hz, 1650Hz, 1850Hz, 2100Hz
– G3 training: 33600, 31200, 28800, 26400, 21600, 14400,

12000, 9600, 7200, 4800, 2400 bps

1. Press Setup.

2. Press Menu until ‘Modem Test’ displays.

DTMF Test

This feature lets the user or tester verify that the phone keypad
buttons are working correctly.

1. Press Setup.

2. Press Menu until “DTMF Test” displays.

3. Press Start.

To test each button, press each button one at a time. There is a
different tone for each button. Each pressed button displays a
corresponding number or symbol in the LCD. If any button fails,
replace the operator panel.

ROM Test

Display ROM version and checksum.

1. Press Setup.

2. Press Menu until ‘ROM Test’ displays.

3. Press Start or Setup.

Modem Speed

Default=33600 bps
Select baud rate of 33600, 28800, 14400, 12000, 9600, 7200, 4800

or 2400 bps. The lower the baud rate, the larger the acceptable error
rate. T30 protocol has a fixed speed of 300 bps in the protocol mode.
When the TX speed is set to 33600 or 28800 bps, the RX speed is
either V.34 V.17 or V.33. When the TX speed is set to 14400 or

3-10 Service Manual

4412-001

12000 bps, the RX speed is either V.17 or V.33. When the TX speed
is set to 9600 or 7200 bps, the RX speed is V.29 or V.27. When the
TX speed is set to 4800 or 2400 bps, the RX speed is V.27.

1. Press Setup.

2. Press Menu until ‘Modem Speed’ displays.

3. Press Options to select the TX speed you want. Press Start or

Setup.

Set TX Level

Default=12 dBm
FCC requires that the transmission level be less than -9 dBm. From -

9 dBm to -15 dBm is acceptable. You can set the transmission level
between 0 and -15 dBm in 1 dBm steps using the operator panel
keypad. Accuracy is +0/-3 dBm.

1. Press Setup.

2. Press Menu until ‘Set TX Level’ displays.

3. Enter a number from 1 through 15 on the keypad.

Set RX Level

Default=-43 dBm
Reception level may be too low due to cable losses. If set to -43

dBm, reception sensitivity is between 0 and -43 dBm.

1. Press Setup.

2. Press Menu until ‘Set RX Level’ displays.

3. Enter a number from 40 through 50 on the keypad.

Pause Time

Default=3 seconds
This sets the length of the pause time from 1 through 9 seconds.

1. Press Setup.

2. Press Menu until ‘Pause Time’ displays.

3. Enter a number from 1 through 9 on the keypad.

Diagnostic Aids 3-11

4412-001

3-12 Service Manual

4412-001

4. Repair Information

This chapter explains how to make adjustments to the printer and
how to remove defective parts.

Note: Read the following before handling electronic parts.

Handling ESD-Sensitive P arts

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

• Keep the ESD-sensitive part in its original shipping container (a

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

• Make the least-possible movements with your body to prevent

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

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

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

• Hold the ESD-sensitive part by its edge; do not touch its pins. If

you are removing a pluggable module, use the correct tool.

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

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

• Machine covers and metal tables are electrical grounds. They

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

• Prevent ESD-sensitive parts from being accidentally touched by

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

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

cabinet (case).

• Be extra careful in working with ESD-sensitive parts when cold

weather heating is used because low humidity increases static
electricity.

Repair Information 4-1

4412-001

Adjustments

The user is directed, in the Printer Control program, to perform the
bidirectional alignment adjustments after replacing a print cartridge.

Removal Procedures

The following procedures are arranged according to the name of the
printer part discussed.

CAUTION: Unplug the power cord before removing any parts.

Releasing Plastic Latches

Many of the parts are held in place with plastic latches. The latches
break easily; release them carefully . To remove such parts, press the
hook end of the latch away from the part to which it is latched.

4-2 Service Manual

4412-001

Removals

General Precautions on Removals

When you disassemble and reassemble components, use extreme
caution. The close proximity of cables to moving parts makes proper
routing a must. If components are removed or replaced, any cables
disturbed must be replaced as close as possible to their original
positions. Before removing any component from the machine, note
the cable routing.

When servicing the machine:

• Check to verify that documents are not stored in memory.

• Move the printer cartridge to far right to cap the nozzle.

• Unplug the power cord.

• Use a flat and clean surface.

• Replace only with authorized components.

• Do not force plastic-material components.

• Make sure all components are in their proper position.

Repair Information 4-3

4412-001

CIS White Roller Assembly Removal

1. Open the operator panel.

2. Push the bushing on both ends of the roller slightly inward, and
then rotate it until it reaches the slot as shown. Lift the roller out.

Note: If the roller is dirty. If dirty, wipe it with a soft cloth
dampened with water. If the roller is heavily worn, replace it with
a new one.

4-4 Service Manual

4412-001

Top Cover Assembly Removal

1. Open the operator panel and open the print cartridge
compartment cover. Remov e the white roller assembly . Remove
the six screws as shown.

2. Remove the three screws as shown and remove the top cover
assembly.

Repair Information 4-5

4412-001

Rollers (Drive Feed Roller Assembly, Exit Shaft)
Removal

1. Remove the top cover assembly. See “Top Cover Assembly

Removal” on page 4-5.

2. Take out the rollers from the base assembly.

Note: Clean the surface of the rollers with ethyl alcohol. After wiping
them, you must dry them completely.

4-6 Service Manual

4412-001

CIS (Contact Image Sensor) Removal

1. Remove the top cover assembly. See “Top Cover Assembly

Removal” on page 4-5.

2. Remove the drive feed roller. See “Rollers (Drive Feed Roller

Assembly, Exit Shaft) Removal” on page 4-6.

3. Remove one screw securing the CIS assembly and unplug the
CIS harness. Remove the CIS assembly.

Repair Information 4-7

4412-001

4. Turn the CIS assembly over. Remove one screw to release the
CIS from the bracket.

Note: Be careful not to lose the springs.

Note: Check the glassy surface of the CIS for any stain or scratch. If

stained, wipe off with ethyl alcohol. If it is heavily stained or
scratched, replac e it.

4-8 Service Manual

4412-001

Scanner Motor with Gear Assembly Removal

1. Remove the top cover assembly. See “Top Cover Assembly

Removal” on page 4-5.

2. Unplug the motor connector from the system board. Make sure
the harness is released from hooks securing the harness as
shown.

Repair Information 4-9

4412-001

3. Remove two screws as shown and remove the scan motor
assembly.

4. Remove the two screws securing the motor to the motor
bracket.

4-10 Service Manual

4412-001

Power Supply Removal

1. Remove the top cover assembly. See “Top Cover Assembly

Removal” on page 4-5.

2. Remove screw from left side and the ground wire on the right.

3. Disconnect connector CON1 from power supply.

4. Lift up and remove.

Repair Information 4-11

4412-001

Line Interface Board Removal

1. Remove the top cover assembly. See “Top Cover Assembly

Removal” on page 4-5.

2. Remove the one screw securing the ground wires to the
bracket.

3. Unplug the line interface connector from the line interface
board.

4. Remove the screw from the ground wire on the power supply.

5. Pull the snaps as shown to unlock the line interface board from
the system board. Push up on the line interface board.

6. Unplug all the connectors from the line interface board and
remove it.

4-12 Service Manual

4412-001

Operator Panel Assembly Removal

1. Remove the top cover assembly. See “Top Cover Assembly

Removal” on page 4-5.

2. Disconnect the operator panel cable from the system board.

3. Release harness from harness hook.

4. Remove the two ground strap screws.

5. Turn the tie stopper 90 degrees as shown and remove from
operator panel assembly.

6. Release ground strap cable hooks.

7. Release opposite operator panel hinge.

Repair Information 4-13

4412-001

Printer Unit Removal

1. Remove the top cover assembly. See “Top Cover Assembly

Removal” on page 4-5.

2. Remove the paper support extension.

3. Release lower paper guide tabs.

4. Release upper paper guide tab.

5. Remove the paper guide.

6. Remove the paper deflector.

7. Remove three screws securing the printer unit, and unplug the
eight connectors from the system board. Remove the printer
unit.

4-14 Service Manual

4412-001

8. Remove ground strap screw.

Note: When you reassemble the unit, do not pinch or short the wire
harness.

ASF Assembly Removal

1. Remove the top cover assembly. See “Top Cover Assembly

Removal” on page 4-5.

2. Remove paper support extension.

3. Release lower paper guide tabs.

4. Release upper paper guide tab.

5. Remove paper guide.

6. Remove paper deflector.

7. Release cables from guides located on ASF assembly.

8. Remove two screws.

9. Remove power supply. See“Power Supply Removal” on

page 4-11.

10. Remove the three screws from the ASF assembly.

Repair Information 4-15

4412-001

11. Remove ASF assembly.

4-16 Service Manual

4412-001

Maintenance Station Removal

1. Remove the printer unit.

2. Remove one screw.

3. Release two tabs from the rear of the maintenance station and
remove the maintenance station.

Repair Information 4-17

4412-001

Carrier Assembly with Belt Removal

1. Remove the printer unit. See “Printer Unit Removal” on

page 4-14.

2. Disconnect the carrier cables from the system board.

3. Release tab on carrier cable guide.

4. Release carrier cable guide from frame.

5. Remove pulley stopper.

6. Depress the belt tensioner and remove the belt from the carrier
motor.

7. Remove two carrier springs that secure the shaft.

8. Remove the carrier shaft.

9. Remove the carrier assembly.

4-18 Service Manual

4412-001

System Board Removal

1. Remove the top cover assembly. See “Top Cover Assembly

Removal” on page 4-5.

2. Remove two screws securing the system board.

3. Unplug all connectors.

4. Pull the sensor lever toward you and remove the system board.

Repair Information 4-19

4412-001

Mid Frame Assembly with Exit Rollers Removal

1. Remove the top cover. See “Top Cover Assembly Removal”

on page 4-5.

2. Remove the carrier assembly.

3. Remove the maintenance station.

4. Remove the encoder strip.

5. Remove two screws from friction roller assembly.

6. Remove exit roller assembly.

7. Release four springs on small feed roller assembly.

8. Press down and remove each lower portion section of the small
feed roller assembly.

9. Release tabs in upper portion of small feed roller assembly.

10. Remove upper portion of small feed roller assembly.

11. Push up on mid frame assembly to release from large feed
roller.

12. Remove mid frame assembly.

4-20 Service Manual

4412-001

Large Feed Roller Assemb l y with Gea r Removal

1. Remove the printer unit. See “Printer Unit Removal” on

page 4-14.

2. Remove the mid frame assembly. See “Mid Frame Assembly

with Exit Rollers Removal” on page 4-20.

3. Remove the maintenance station.

4. Remove the feed roller bearing from the main frame. Pull the
feed roller as shown and remove.

Repair Information 4-21

4412-001

Paper Feed Motor Assembly with Gears Removal

1. Remove the printer unit. See “Printer Unit Removal” on

page 4-14.

2. Remove the large feed roller assembly. See “Large Feed

Roller Assembly with Gear Removal” on page 4-21.

3. Remove the two screws and remove the paper feed motor
assembly.

4-22 Service Manual

4412-001

Carrier Transport Motor Removal

1. Remove the top cover assembly. Go to the “Top Cover

Assembly Removal” on page 4-5.

2. Manually move the carrier to the center of the machine.

3. Remove the idler pulley assembly spring cover retainer.

4. Press the idler pulley and remove the belt from the carrier
transport pulley.

5. Disconnect connector (P4) from the system board.

6. Remove the two screws from the carrier transport motor and
remove.

Repair Information 4-23

4412-001

4-24 Service Manual

4412-001

5. Connector Locations

System Board

Units Description

P1 Power Supply
P2 CIS
P4 Carrier Motor
P5 Paper Feed Motor
P6 Scanner Motor
P7 Carrier Cable
P8 Line Interface Board
P9 Operator Panel
P10 Speaker
P11 Door Switch

Connector Locations 5-1

4412-001

Line Interface Board

Units Description

P1 System Board

5-2 Service Manual

4412-001

Power Supply

Units Description

CON1 System Board

Connector Locations 5-3

4412-001

5-4 Service Manual

4412-001

6. Preventive Maintenance

This chapter contains the lubrication specifications. Follow these
recommendations to prevent problems and maintain optimum
performance.

Lubrication Specifications

Lubricate only when parts are replaced or as needed, not on a
scheduled basis. Use grease P/N 99A0394 to lubricate the following:

• All gear mounting studs.

• The left and right ends of the large feed roller at the side frames.

• The carrier to carrier frame engagement.

• The carrier guide rod and carrier guide rod bearings.

Preventive Maintenance 6-1

4412-001

6-2 Service Manual

4412-001

7. Parts Catalog

How to Use This Parts Catalog

• SIMILAR ASSEMBLIES: If two assemblies contain a

majority of identical parts, they are shown on the same list.
Common parts are shown by one index number. Parts
peculiar to one or the other of the assemblies are listed
separately and identified by description.

• NS: (Not Shown) in the Asm-Index column indicates that the

part is procurable but is not pictured in the illustration.

• PP: in the parts description column indicates the part is

available in the listed parts packet.

• NA: Not available as a FRU.

Parts Catalog 7-1

4412-001

Assembly 1: Main Assembly

7-2 Service Manual

4412-001

Assembly 1: Main As se mb ly

Asm­Index

Part
Number

1-1 56P1152 1 Support, Paper Extension

2 56P1151 1 Guide, Paper
3 56P1150 1 Deflector, Paper
4 56P1154 1 Cover, Top Assembly
5 56P1153 1 CIS White Roller Assembly
6 56P1155 1 Tray, Paper Exit Assembly
7 56P1156 1 Tray, Scan Exit Assembly
8 56P1178 1 Screw /Ring s Parts Packet
9 56P1160 1 Panel, Operator Assembly

Units Description

Parts Catalog 7-3

4412-001

Assembly 2: Base Unit

7-4 Service Manual

4412-001

Assembly 2: Base Unit

Asm­Index

N/S 56P1179 1 Cable, Line Interf ac e

Part
Number

2-1 12G6972 1 Phone Line Cord

2 12G6971 1 Power Line Cord
3 56P1157 1 Board, Line Interface
3 56P1180 1 Board, Line Interface (EMEA)
3 56P1181 1 Board, Line Interface (Taiwan)
3 56P1182 1 Board, Line Interface (PRC)
4 56P11 58 1 Power Supply
5 56P1161 1 Base Assembly
6 56P1164 1 Motor, Scanner with Gear Assembly
7 56P1165 1 Motor, Carrier Assembly
8 12G6948 1 Shaft, Exit

9 12G6941 1 Drive Feed Roller As sembly
10 12G6949 1 Strap, Operator Panel Door
11 12G6950 1 Spring, Ground
12 56P1166 1 Sensor, Access Door
13 12G6953 1 Latch, Operator Panel Door
14 56P1162 1 Contact, Image Sensor (CIS)
15 12G6944 1 Spring, CIS
16 12G6945 1 IPR-Bracket CIS
17 56P1163 1 Cable CIS

Units Description

Parts Catalog 7-5

4412-001

Assembly 3: Engine

7-6 Service Manual

4412-001

Assembly 3: Engine

Asm­Index

Part
Number

3-1 56P1167 1 ASF Assembly

2 12G6961 1 Small Feed Roller Assembly with EOF and

3 56P1159 1 System Board

4 56P1172 1 Main Frame Assembly with Encoder Clip

5 56P1169 1 Cable, Transport Carrier Motor

6 56P1168 1 Motor, Carrier Transport

7 12G6965 1 Spring, Carrier Sha ft Retainer

8 12G6956 1 Maintenance Station Assembly

9 12G6966 1 Bearing, Feed Roller
10 12G6962 1 Feed Roller, Large with Gear
11 12G6964 1 Frame, Mid Assembly with Exit Rollers
12 56P1171 1 Carrier Belt
13 12G6968 1 Strip, Encoder
14 56P1170 1 Carrier Assembly with Belt
15 56P1173 1 Clip, Encoder
16 12G6967 1 Shaft, Carrier
17 12G6958 1 Stopper Pulley
18 12G6957 1 Pulley, Idle Assembly
19 12G6963 1 Motor, Paper Feed Assembly with Gears

Units Description

Springs

Parts Catalog 7-7

4412-001

7-8 Service Manual

4412-001

Index

A

Abbreviations 1-5
Adjustments
Aging Test
Answer On Rings
Auto Journal
Auto Reduction

4-2

3-5

3-9

3-6

3-8

C

CIS Test 3-5
Connector Locations
Contact Image Sensor

5-1

3-2

D

Diagnostic Aids 3-1
Diagnostic Informatio n
Dial Mode
Discard Size
Drive Feed Roller
DTMF Test

3-7

3-8

3-10

2-1

3-1

E

ECM 3-7
ESD-Sensitive Parts

4-1

G

General Information 1-1

L

Line Interface Board 5-2
Lubrication Specifications

M

Maintenance 3-6
Message Confirm
Modem Speed
Modem Test

3-6

3-10

3-10

P

Parts Catalog 7-1
Pause Time

3-11

6-1

Plastic Latches 4-2

2-1

POST
Power Supply
Preventive Maintenance
Print Report
Print RTI
Problems

Carrier Transport
Maintenance Station
Operator Panel
Paper Feed
Power
Print Quality
Printer Communication
Scanner

Program Download

5-3

3-5

3-9

2-3

2-3

2-6

2-6

2-6

2-5

3-6

R

Remote RCV Code 3-7
Removal Procedures
Removals

ASF Assembly 4-15
Carrier Assembly
Carrier Transport Motor
CIS White Roller
Contact Image Sensor
Large Feed Roller
Line Interface Board
Maintenance Station
Mid Frame Assembly
Operator Panel
Paper Feed Motor
Power Supply
Printer Unit

4-6

Rollers
Scanner Motor
System Board

Top Cover Assembly
Repair Information
Retry Count
Retry Interval
ROM Test

3-9

3-8

3-10

4-2

4-18

4-4

4-21

4-13

4-22

4-11

4-14

4-9

4-19

4-1

6-1

2-3

2-5

4-23

4-7

4-12

4-17

4-20

4-5

Index I-1

4412-001

S

Safety Information v
Service Checks

Carrier Transport 2-7
CIS Assembly
Maintenance Station
Paper Feed
Paper Path

2-15

Power
Print Quality
Scan/Copy Quality

Scanner Motor
Service Mode
Set RX Level
Set TX Level
Specifications

Facsimile 1-3

Power and Size

Printer Engine

Printhead

Scanner
Symptom Table (POST)
Symptom Tables
System Board

2-9

2-12

2-14

2-16

2-10

3-2, 3-4
3-11
3-11

1-5

1-2

1-2

1-5

2-3

5-1

T

Theory of Mechanism

Contact Image Sensor
Document Sensors
Drive Feed Roller Assembly
Scanner

3-1

U

User Mode 3-3

Part Numbers

12G6941 7-5
12G6944
12G6945
12G6948
12G6949
12G6950
12G6953
12G6956
12G6957

7-5
7-5
7-5
7-5
7-5
7-5
7-7
7-7

2-11

2-18

2-2

3-2

3-2

3-1

12G6958
12G6961
12G6962
12G6963
12G6964
12G6965
12G6966
12G6967
12G6968
12G6971
12G6972
56P1150
56P1151
56P1152
56P1153
56P1154
56P1155
56P1156
56P1157
56P1158
56P1159
56P1160
56P1161
56P1162
56P1163
56P1164
56P1165
56P1166
56P1167
56P1168
56P1169
56P1170
56P1171
56P1172
56P1173
56P1178
56P1179
56P1180
56P1181
56P1182

7-7
7-7
7-7
7-7
7-7
7-7
7-7
7-7
7-7
7-5

7-5
7-3
7-3
7-3
7-3
7-3
7-3
7-3
7-5
7-5
7-7
7-3
7-5
7-5
7-5
7-5
7-5
7-5
7-7
7-7
7-7
7-7
7-7
7-7
7-7
7-3
7-5
7-5
7-5
7-5

I-2 Service Manual